The application of Automated Optical Inspection

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Introduction to Optical Inspection

• Helge Jordfald
• Sales Marketing Manager
• Tordivel AS Norway

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Content

• Why Automated Optical Inspection?
• How does it work?

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Why Automated Optical inspection?

• To improve production and reduce cost through
• Quality Control
• Flaw detection
• Yield Management
• Factory Automation

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Alternatives

• Manual Control
• Sample Control
• Mechanical Control
• Photo Sensor Control
• No Control

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Manual versus Automated

• Manual Inspection
• Varies over time and with different persons
• Monotonous work
• Automated Optical Inspection
• Fixed quality over time
• High speed
• Traceability and documentation

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Quality Control

• Zero faults to customers
• 100 control instead of sample control
• Objective and constant quality control
• Use Vision Control as sales argument

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Flaw Detection

• Reduce added value to defective parts
• Identify and remove products with flaw early in
  the production line
• Use several inspection station
• Reduce materiel consumption
• Increase your production capacity

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Yield Management

• Monitor changes in production performance
• Do corrections before the yield is reduced
• Real time statistics and trends

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Flexible Automation

• Increase production efficiency and flexibility
  by
• Automatic guiding of robots for picking and
  packing products
• Automatic product sorting and program selection

• Reduce inspection costs
• Improve Health, Environment and Safety
• Automate heavy and monotonous manual job functions

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How does it work?
Magic?

• System components
• Resolution and tolerances
• Basic image processingtechniques

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Basic system

• Standard PC
• One or more cameras
• Illumination
• Mounting system and protection for light and
  cameras
• Communication interface to Control System

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The Optical System

• Camera
• CCD array, Line camera, Area camera
• Analogue or Digital signal transmission
• Lenses
• Adapted to the individual applications
• An Optical System
• A picture of a physical area (FOV Field Of
  View)
• With a specified resolution
• With a minimum of optical distortion (compromise)

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Illumination

• The key to a good and reliable Vision system
• An increasing number of specialised lighting
  sources for different applications
• Fiber, LED, Laser
• On-Axis, Cloudy Day, Darkfield
• Selection of lighting source a job for experts

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Communication with the production line

• Logical
• Trigger Take image
• Answer Result
• Physical - Electrical
• 24 volt isolated
• RS-232, Ethernet tcp/ip
• Protocols to robot, PLC and web
• TDVCmdProtocol RS-232 - TCP/IP
• OPC ip profibus (PLC and PC systems)

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Graphical User Interface
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Process insight
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Documentation
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Camera - Field of View
Pixels in Y direction
Piksels in X direction
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Grey scale pictures
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Pixel resolution

• VGA Camera
• 640 x 480 pixels
• FOV 5mm x 5mm
• Resolution ca. 0,01mm
• FOV 50mm x 50 mm
• Resolution ca. 0,1mm
• FOV 500mm x 500mm
• Resolution ca. 1 mm

• High Res. Camera
• 1024 x 768 pixels
• FOW 5mm x 5mm
• Resolution ca. 0,005mm
• FOW 50mm x 50 mm
• Resolution ca. 0,05mm
• FOW 500mm x 500mm
• Resolution ca. 0,5 mm

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Example - Pixel Resolution
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Gauging

• Intensity level variations along the line.
• Simple gauging ofdistance
• Measure the distance between two intensity levels

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Improving the result

• Filtering

• Using geometry

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Calibration

• Transforming pixel to a dimensional unit (mm)
• Corrections for distortion in the optical system
  (camera and lens)
• Using GRID
• Calibration only related to one measurement plane
• Scorpion Vision Software can be calibrated in
  many planes

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Other advantages using Calibration

• Large Objects

• Perspective

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How to build an inspection

• Perform and validate a number of simple
  measurements
• Dimension
• Lines
• Greyscale values colour
• A set of these measurements are combined to
  identify specific Conditions

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Image processing example
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