An appearance inspection apparatus for electroplated electronic components

Abstract

This invention discloses a visual inspection device for electroplated electronic components. The device includes an adjustable streamline, a carrier positioning mechanism, and multiple camera modules. The adjustable streamline consists of a conveying mechanism and a pair of adjustable-width guide rails. The guide rails are adjusted by a width adjustment mechanism to accommodate carriers of different sizes. The conveying mechanism drives the carrier to move along the inspection direction. The carrier positioning mechanism is located in the inspection area in the middle of the streamline and is used to fix the carrier carrying the electroplated component at a predetermined inspection position. The camera modules are mounted above the adjustable streamline. A first set of three-axis inspection modules carries two camera modules, used to sequentially photograph the first and third positions on the carrier; a second set of three-axis inspection modules carries the remaining two camera modules, used to sequentially photograph the second and fourth positions on the carrier. Through this structure, adaptation to carriers of different sizes and full coverage inspection of multiple positions on electronic components are achieved, improving the accuracy and efficiency of visual inspection.

Description

Technical Field

[0001] This invention relates to the field of electronic component inspection technology, and more specifically to an appearance inspection device for electroplated electronic components. Background Technology

[0002] With the miniaturization and high performance of electronic products, an increasing number of electronic components require electrochemical plating to improve conductivity, corrosion resistance, and surface reliability. While electrochemical plating can significantly improve product performance, it is prone to generating various surface defects, such as dents, scratches, particles, bulges, incomplete plating, over-plating, discoloration, plating misalignment, and misalignment of QR codes and LDS markings. These defects not only affect the product's appearance but may also reduce electrical performance or cause component failure. Therefore, high-precision and high-efficiency visual inspection of electroplated electronic components is of great significance.

[0003] Existing inspection methods mainly fall into two categories: one is manual visual inspection, which relies on the operator's experience and judgment, resulting in high labor intensity, susceptibility to human factors, low efficiency, and poor accuracy; the other is automated inspection systems based on ordinary industrial cameras, which analyze surfaces through image acquisition and simple algorithms. However, these systems have the following shortcomings: Common conveyor line widths are fixed, making it difficult to adapt to carriers of electronic components of different sizes or array arrangements. The number of cameras is limited, and the shooting angle is singular, making it impossible to fully cover multiple inspection positions, easily leading to missed defects. The lack of carrier positioning or blocking mechanisms may cause carrier shifting during transport, resulting in unstable image acquisition. Vibration and uneven lighting can easily degrade image quality, thus affecting subsequent judgment results. Some existing equipment lacks an automatic NG rejection module, requiring manual sorting and reducing the overall level of automation. Summary of the Invention

[0004] This invention provides an appearance inspection device for electroplated electronic components, aiming to solve the problems of poor adaptability, insufficient inspection coverage, inaccurate positioning, and lack of automatic rejection function in existing inspection equipment.

[0005] The device includes an adjustable conveyor system consisting of a conveying mechanism and a pair of adjustable-width guide rails. The guide rails are adjustable via a width adjustment mechanism to accommodate carriers of different sizes. The conveying mechanism drives the carrier to move smoothly along the detection direction. To ensure the stability and repeatability of the detection, a carrier positioning mechanism is located in the middle of the adjustable conveyor system to fix the carrier holding the electroplated part at a predetermined detection position, ensuring that the carrier does not shift during the imaging process.

[0006] Multiple camera modules are installed above the detection area, each mounted on a corresponding three-axis detection module. Specifically, the first three-axis detection module carries two camera modules to sequentially capture images of the first and third positions on the vehicle; the second three-axis detection module carries the remaining two camera modules to sequentially capture images of the second and fourth positions on the vehicle. By coordinating the movement of the three-axis detection module with multiple camera modules, coverage of multiple detection positions is achieved, improving the completeness and accuracy of the detection.

[0007] To accommodate products of different sizes, the width adjustment mechanism is designed with two movable guide rails, which can be driven by a lead screw or an electric push rod to adjust the streamline width within a range of 100-150mm. Each camera module is equipped with an independent optical lens and illumination device, which includes a coaxial light source and a ring light source. The ring light source and the coaxial light source are respectively mounted coaxially with the lens, allowing different types of defects to be displayed under optimal lighting conditions.

[0008] In addition, the testing equipment also includes a computer system installed in the electrical control box. This computer system mainly consists of a main processing unit, an image acquisition card, an industrial control interface card, a data storage unit, and a display interface. The main processing unit is used for control and data processing; the image acquisition card is electrically connected to the camera module and is used to receive and store image signals; the industrial control interface card is electrically connected to the triaxial detection module, the adjustable streamline drive mechanism, the blocking mechanism, and the NG rejection module, respectively, and is used to send control signals and drive the corresponding components to move; the data storage unit is used to save the detection images and detection results; and the display interface is connected to the human-machine interface and is used to display the detection status, detection results, and equipment operating parameters in real time.

[0009] To automatically reject non-conforming products, the equipment is equipped with an NG rejection module. This module includes a cylinder-driven push rod or guide plate. When the camera completes its capture and the computer system determines that the product is non-conforming, the push rod extends and pushes the non-conforming carrier into the rejection track. If the product is deemed acceptable, the push rod remains retracted, and the carrier continues to move along the flow line to the unloading position, thereby achieving automatic sorting.

[0010] The carrier is a support with an array structure, capable of accommodating multiple electronic components to be tested, and is equipped with an auxiliary positioning device so that the system can accurately identify the coordinates of unqualified components, thereby achieving precise positioning and rejection.

[0011] This invention adopts an adjustable streamlined structure. The guide rail is adjustable via a lead screw or electric push rod, and its width can be flexibly varied from 100 to 150 mm, thereby being compatible with different specifications of vehicles and improving the versatility and adaptability of the equipment.

[0012] The equipment is equipped with two sets of three-axis detection modules, carrying a total of four camera modules, which can sequentially cover and photograph multiple detection positions on the vehicle. The multi-angle, multi-light source imaging method ensures the integrity of the detection coverage and avoids missed detections.

[0013] Each camera module is equipped with an independent optical lens and lighting device. The lighting includes coaxial light sources and ring light sources, which are installed coaxially with the lens. The lighting mode can be flexibly selected according to the inspection requirements, so that different defects can be displayed under the best conditions.

[0014] The present invention includes an NG rejection module, in which a push rod or guide plate driven by a cylinder automatically moves when a defective item is determined to be defective, pushing the defective carrier out of the flow line, while the qualified carrier continues to move forward to the unloading position, thereby realizing automatic sorting and improving production line efficiency.

[0015] This invention integrates a computer system into an electrical control box, including a main processing unit, an image acquisition card, an industrial control interface card, a data storage unit, and a display interface. It realizes the integration of image acquisition, data storage, actuator control, and human-machine interaction, which greatly improves the automation and operating efficiency of the equipment.

[0016] The appearance inspection equipment described in this invention is particularly suitable for electronic components whose surfaces have undergone electrochemical plating treatment, such as antenna products. It can efficiently and accurately detect plating defects, marking misalignment, and appearance flaws, and achieves integrated detection, judgment, and rejection through an automated structure, thereby improving production efficiency and product quality control. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of an electronic component antenna that has undergone electrochemical plating treatment.

[0018] Figure 2 This is a schematic diagram of the overall structure of the appearance inspection device of the present invention;

[0019] Figure 3 This is a schematic diagram of the NG rejection module and related conveying structure of the present invention;

[0020] Figure 4 This is a schematic diagram of the carrier structure used to support the antenna;

[0021] Figure 5 This is a schematic diagram of the camera capturing device in the testing equipment;

[0022] Figure 6 This is a schematic diagram of the computer system architecture of the present invention.

[0023] Figure 7 This is a flowchart of the appearance inspection method of the present invention; Detailed Implementation

[0024] See Figure 1 As shown, the electronic component antenna 110 of the present invention has an overall elongated strip structure. Its left end is provided with a relatively wide front end connection portion 111, which has a stepped limiting step 112 for positioning in conjunction with a carrier or fixing mechanism. The antenna body 113 is an elongated straight rod with multiple longitudinally extending long strip grooves or plating areas 114 on its surface to ensure the uniformity of the electroplating layer distribution and facilitate detection and identification. The middle area of ​​the body 113 transitions into a tapered contraction section 115. This tapered design can improve the overall stress distribution and reduce dead angles during processing. A narrow tail plug portion 116 is formed at the right end of the antenna 110. This end serves as a signal lead-out or electrical connection end for achieving a stable electrical connection with external circuits.

[0025] After the main body of antenna 110 is processed, a dense and uniform metal coating is formed on its surface through an electrochemical zinc plating process. This coating covers the main body rod, the transition cone section, and the tail end insertion part, which not only significantly improves the antenna's corrosion resistance but also reduces surface contact resistance, ensuring the stability and reliability of signal transmission. At the same time, the zinc plating layer has good gloss and uniformity, which makes it easy to reveal defects such as scratches, dents, particles, bulges, incomplete plating, over-plating, and discoloration during the appearance inspection process using a combination of coaxial light source and ring light source illumination. This provides a reliable structural basis for subsequent testing equipment to achieve efficient and accurate judgment.

[0026] like Figure 4 As shown, when the antenna is tested, it is placed in a carrier. The carrier 700 adopts a plate array structure 701. The plate surface is evenly opened with cavities 702 that match the shape of the antenna under test, forming a regular array in each row and column. Several protrusions / steps 705 and lateral micro-clamps 706 are set in each cavity 702 to achieve rapid positioning and limiting of individual components and prevent attitude changes caused by line vibration. Identification references 707 (such as circular holes or grooves 708) are made on the edge of the carrier 700. Before entering the shooting position, the camera module 401 reads the reference 707 and the QR code to establish the association between the array coordinate system and the carrier 700 ID, so as to accurately map the coordinates of each subsequent unqualified electronic component to the array index and physical coordinates. Considering the obstruction of the light path by the cavity 702, in this embodiment the camera takes pictures vertically and prioritizes the detection of the middle area. When it is necessary to extend to the lower edge of the curved surface, diffuse reflection matting texture and local light-transmitting window can be added to the side wall of the cavity 702 without changing the outer contour of the carrier 700, so as to reduce the influence of shadows and glare on imaging.

[0027] Furthermore, the carrier 700 should preferably be made of dimensionally stable, temperature-resistant, and chemically resistant engineering plastics or composite materials, and its surface should be sandblasted / matte-treated to reduce reflection. The carrier 700 should be refluxing and dried before being put into operation to avoid residual liquid affecting the detection.

[0028] like Figure 2 As shown, the appearance inspection equipment for electroplated electronic components in this embodiment adopts a mechatronics architecture, consisting of a frame 100, an adjustable flow line 200, a carrier positioning mechanism 300, a blocking mechanism 301, two sets of triaxial inspection modules 400 and four camera modules 401 mounted on them, a human-machine interface 800, an electrical control box 500, and a material unloading station 600 located at the end of the flow line and an NG rejection module 601 on the side. The overall spatial outline and installation layout of the machine can be referred to Figure 3 , Figure 4 The 3D prototype shown occupies approximately 1200mm × 800mm of space and is about 900mm high, facilitating its placement on a standard production line. The machine is equipped with casters 101 and leveling feet 102 at the bottom for quick leveling and fixation after installation. The electrical control box 500 is centrally located below the machine for easy wiring, maintenance, and dust control. An adjustable flow line 200 runs longitudinally through the upper working area of ​​the machine, handling the transport, positioning, and release of the carrier 700.

[0029] Two sets of triaxial detection modules 400 are straddled on the crossbeam 408 above the streamline. The first set of triaxial detection modules 400 carries two sets of camera modules 401 and is responsible for sequentially photographing the first and third detection positions 711 and 713 on the vehicle 700. The second set of triaxial detection modules 400 carries the remaining two sets of camera modules 401 and sequentially photographs the second and fourth detection positions 712 and 714, forming an alternating coverage of "1, 3-2, 4", ensuring full coverage of the effective area of ​​the entire vehicle 700 with a limited number of cameras.

[0030] The adjustable conveyor 200 consists of a pair of parallel guide rails 201 and a conveyor belt / chain plate between them. The two guide rails 201 are respectively fixed on a slide base 203 that can slide laterally. The slide base 203 is connected to the frame 100 through a set of blocking mechanisms 301 on the left and right. When adjusting the width of the adjustable conveyor, the spacing of the blocking structures on the opposite side needs to be adjusted synchronously to adapt to the width change of the adjustable conveyor.

[0031] Reference Figure 5 Each camera module 401 is composed of an industrial camera 402, a telecentric lens 403, a coaxial light source 404, and a ring light source 405. The lens is preferably a telecentric lens 403 to obtain near-perspective distortion-free, equal-magnification imaging, which facilitates accurate measurement of dimensions and judgment of positional deviation. The coaxial light source 404 couples light to the imaging optical path through a 45° beam splitting structure 420. Coaxial high-brightness exposure can illuminate the metal mirror surface and suppress diffuse reflection background, which is beneficial for observing the continuity of the coating, the interface of misplating / missing plating, and the QR code printing area. The ring light source 405 is installed in the coaxial support 406 below the lens barrel. The angle can be finely adjusted and is used for high-contrast display of surface morphology defects such as scratches, dents, particles, and discoloration.

[0032] The structural height from the lens to the coaxial illumination module is approximately 220±20mm, and the working distance from the bottom of the lens to the product under test is approximately 40±20mm. The working distance is compensated by the Z-axis travel of the 400mm triaxial inspection module, ensuring both field of view coverage and balancing resolution and depth of field. Within one inspection cycle, three images are captured sequentially for the same inspection position using coaxial low exposure, coaxial high exposure, and ring light. The coaxial low exposure enhances the outline of fine scratches and indentations, the coaxial high exposure is used to determine the continuity of plating misalignment and metal coverage, and the ring light is used for QR code recognition / offset and contrast-dependent defect characterization such as over-plating and missing plating.

[0033] To mitigate the light-blocking effect of the array carrier 700 cavity 702, the camera's line of sight is kept aligned with the normal direction of the product surface. The X / Y micro-shift of the three-axis detection module 400 is used to correct the overlapping areas of adjacent positions, improving the overall coverage after stitching. For uneven lower-edge illumination at edge workstations caused by the curved cavity 702, this is alleviated by adding lateral supplementary lighting strips or optimizing the angle of the local ring light 405. The four camera modules 401 are assembled with two spans 408, two cameras per span. The two cameras on the first span 408 cover the first and third workstations, and the two cameras on the second span 408 cover the second and fourth workstations. Rigid reinforcing ribs or vibration damping pads are provided on the spans 408 to prevent high-frequency vibrations from being transmitted to the lens barrel and causing imaging jitter.

[0034] The electronic component under inspection is an antenna device whose surface has undergone electrochemical plating treatment, such as... Figure 1 The main body shown is a slender component with segmented dimensions of approximately 11.45, 8.23, and 7.75 mm in length. It features connection / positioning characteristics at the ends and a combination of metal-plated areas and exposed substrate areas on its surface. This embodiment addresses this type of elongated, highly reflective metal part by making three optical and process adaptations: First, the telecentric lens 403 combines constant magnification imaging with high-brightness exposure from the coaxial light source 404 to detect plating continuity, misplating / missing plating stripes, QR code printing area offset, and readability. The coaxial light effectively suppresses diffuse reflection from the substrate, highlighting the metal area boundaries. Second, the ring light source 405 emphasizes surface micro-morphological differences at lower exposure, giving higher grayscale contrast to "minor undulation" defects such as scratches, dents, particles, and bulges. Third, the shape of the array carrier 700 cavity 702 closely matches the antenna shape, and a light-transmitting area is reserved near the QR code to avoid recognition failure caused by cavity wall obstruction.

[0035] like Figure 3As shown, the NG removal module 601 is installed at the end of the adjustable streamline and located on the side of the main channel. The main body of the module consists of a push rod 602 driven by a cylinder and a guide rail 603. The extension stroke of the push rod and the geometry of the guide plate are optimized through simulation so that the defective antenna on the target vehicle 700 can be extracted and released by the extraction mechanism (such as a suction cup or magnetic head) without interfering with the adjacent vehicle 700.

[0036] The NG rejection module 601 is electrically connected to the industrial control interface card of the computer system 501, and receives NG signals and cycle synchronization signals from the judgment unit. It only operates within the time window when the judgment is unqualified and the carrier 700 is in place. When the judgment is qualified, the push rod remains in the retracted state, and the carrier 700 enters the unloading position 600 along the flow line to realize automatic sorting and reduce manual intervention. To improve safety, the rejection area is equipped with a transparent protective cover and a cover-opening power-off switch 608 to facilitate observation and prevent accidental entry.

[0037] like Figure 6 As shown, the computer system 501 is integrated into the electrical control box 500 at the bottom of the machine. It uses an industrial PC 502 as the main processing unit and is equipped with multiple gigabit Ethernet ports 503 to connect to four industrial cameras 402. A matching image acquisition card / network card 504 is used to stably receive high-bandwidth image streams. Motion control and I / O control are concentrated on a multi-axis motion control card / PLC 505. The control card / PLC 505 is connected via a bus 400 to the servo drivers 506 of two sets of three-axis detection modules 400, an audible and visual alarm, and the solenoid valve of the NG rejection module 601. The data storage unit 507 is used to save original images, detection results, and traceability logs. The display interface is connected to the human-machine interface display 801 above via DP / HDMI 800 to display the workstation status, current batch progress, and NG statistics in real time.

[0038] After the system powers on and performs a self-test, it first reads batch information from the carrier 700ID / QR code or the line MES, and then automatically calls up camera parameters and exposure combinations according to the product type. When the carrier 700 reaches the shooting position and stops, the main processing unit 720 triggers the acquisition of three lighting sequences from each camera in parallel. The images are localized and preprocessed in real time before being output for judgment. The motion control card / PLC505 issues "release / reject" IO commands based on the judgment results and updates the count and yield curve on the human-machine interface display 801.

[0039] In actual operation, the system follows Figure 7 The process shown first performs cropping and normalization on the original image, then binds the images of the four detection positions with the position index, and outputs the coordinates and defect category of the antenna in the array; when it is determined to be NG, the coordinate information will be written into the rejection queue and the push rod 602 will be driven to move when the carrier 700 moves to the rejection position, so as to complete the precise rejection of the specific carrier 700.

[0040] The specific steps include:

[0041] Step 1: Image Preprocessing

[0042] After the vehicle is positioned at the detection location, the camera acquires the original image using a combination of coaxial and ring light sources. The computer system first preprocesses the acquired original image, including grayscale equalization, background filtering, noise removal, and size normalization, to ensure the stability and consistency of the image data during subsequent recognition.

[0043] Step 2: Defect Area Location and Cutting

[0044] In the preprocessed image, the system accurately locates the actual position of the antenna based on the carrier reference or QR code coordinates, and cuts out the corresponding image area to form an effective detection image of the individual electronic component. This step ensures that the image data of each product in the array is correctly extracted.

[0045] Step 3: Defect Sample Labeling and Training

[0046] The cropped individual images are fed into the defect training module, where samples are labeled manually or semi-automatically. Labeling includes defect categories such as scratches, dents, particles, bulges, unplated areas, over-plated areas, and color variations. The labeled dataset is then input into deep learning software to construct a convolutional neural network model for feature extraction and classification of defect features.

[0047] Step 4: Model Training and Export

[0048] Deep learning software undergoes iterative training with a large number of samples to obtain a reasoning model capable of accurately identifying different defects. After training is complete, the model parameters are exported to generate a deployable recognition model file, which is then interfaced with the computer system of the detection equipment.

[0049] Step 5: Model Deployment and On-site Testing

[0050] The exported recognition model is imported into the industrial PC of the detection equipment. During actual operation, the images captured by the camera in real time are preprocessed and cropped, and then directly input into the model for judgment, outputting the judgment result (OK or NG) and the corresponding coordinate information.

[0051] Step Six: Sorting and Execution

[0052] When the judgment result is OK, the carrier continues to move forward to the unloading position under the drive of the conveyor mechanism; when the judgment result is NG, the industrial control interface card controls the cylinder-driven rejection push rod to push the unqualified carrier out of the main line and into the NG channel, realizing automatic rejection.

[0053] During the overall deployment and commissioning phase, the carrier model 700 and camera parameter group are first selected on the HMI according to the product type. The system automatically drives the width adjustment mechanism to the memory position, and the three-axis detection module 400 is set to the initial posture according to the formula. Subsequently, the field of view consistency and distortion correction of the four camera modules 401 are performed through the reference board 900. After calibration, the results are stored in the data storage unit 507. During trial operation, based on the standard parts provided by the customer, defect samples are gradually added and the display effect under various lighting conditions is verified. If necessary, the angle of the ring light source 405 and the brightness of the coaxial light source 404 are finely adjusted to obtain stable contrast and edge quality. Under long-term operating conditions, the repeatability of the equipment's dimensional measurement is better than 0.02mm, the theoretical resolution of a single pixel is about 0.006mm / pixel, the minor omission rate is less than 0.08%, the major / functional defect omission rate is 0%, and the over-detection rate is less than 5%, meeting the quality control requirements for mass production sampling or full inspection.

[0054] For scenarios requiring a wider channel range or mixed-specification lines, a variant model with an adjustable width range of 150–300 mm is available, with related dimensional calibration and safety travel achieved through software limits. Furthermore, the machine is equipped with a network interface for the MES system, enabling batch information distribution, test data feedback, and SPC report output; after docking with barcode scanners or carriers, it supports full lifecycle traceability of the carrier.

[0055] In summary, this invention proposes a dedicated appearance inspection device and method for electroplated electronic components. Through the organic integration of adjustable streamlines, a carrier positioning mechanism, multiple camera modules, a computer system, and an NG rejection module, it achieves rapid adaptation and high-precision inspection of carriers of different sizes and batches of electronic components. Simultaneously, the use of composite illumination from coaxial and ring light sources, along with the introduction of deep learning algorithms, makes surface defect identification more comprehensive, accurate, and stable. This device not only improves inspection efficiency and coverage but also reduces manual intervention and misjudgment rates.

Claims

1. An appearance inspection device for electroplated electronic components, characterized in that, include: The adjustable flow line consists of a conveying mechanism and a pair of adjustable-width guide rails. The guide rails are adjusted by a width adjustment mechanism to adapt to carriers of different sizes. The conveying mechanism is used to drive the carrier to convey along the detection direction. A carrier positioning mechanism is located in the detection area in the middle of the adjustable streamline, and is used to fix the carrier carrying the electroplated part at a predetermined detection position. Multiple camera modules are mounted above the adjustable streamline, including: The first set of three-axis detection modules carries two sets of camera modules, which are used to sequentially photograph the first and third positions on the vehicle along the streamline; The second set of three-axis detection modules carries the other two sets of camera modules and is used to sequentially photograph the second and fourth positions on the vehicle.

2. The appearance inspection equipment for electroplated electronic components according to claim 1, characterized in that, The width adjustment mechanism includes two movable guide rails, which are driven by a lead screw or an electric push rod, and the width adjustment mechanism can adjust the streamline width within the range of 100-150mm.

3. The appearance inspection equipment for electroplated electronic components according to claim 1, characterized in that, Each camera module is equipped with an independent optical lens and an illumination device, the illumination device including a coaxial light source and a ring light source, and the ring light source and the coaxial light source are respectively mounted coaxially with the lens.

4. The appearance inspection equipment for electroplated electronic components according to claim 1, characterized in that, It also includes a computer system, which is installed inside an electrical control box and includes: The main processing unit is used for execution control and data processing; An image acquisition card, electrically connected to the camera module, is used to receive and store image signals captured by the camera; An industrial control interface card is electrically connected to the triaxial detection module, adjustable streamline drive mechanism, blocking mechanism and NG rejection module, and is used to send control signals and drive the actuators to move. Data storage unit, used to store detection images and detection results; The display interface, connected to the human-machine interface, is used to display the detection status, results, and equipment operating parameters.

5. The appearance inspection equipment for electroplated electronic components according to claim 4, characterized in that, The NG rejection module includes a cylinder-driven push rod or guide plate. After the camera module completes the shooting, the push rod extends according to the judgment result and pushes the unqualified carrier into the rejection track; the qualified carrier remains on the flow line and continues to move forward to the unloading position.

6. The appearance inspection equipment for electroplated electronic components according to claim 1, characterized in that, The carrier is an array structure that accommodates the electronic components to be tested, and the carrier has an auxiliary positioning device to identify the coordinates of the defective electronic components.

7. The appearance inspection equipment for electroplated electronic components according to any one of claims 1-6, characterized in that, The electronic component is an antenna with an electrochemically plated surface.

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