Adhesive Film Defect Marking for Targeted Product Rechecking
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Solution Overview
Problem
The current manufacturing process for product quality control requires significant manual effort for rechecking products with apparent defects, which can lead to additional defects and inefficiencies due to the need for manual confirmation and sorting.
Innovation Solution
An electronic device with a defect detection unit, marking unit, and film coating system that automatically detects defects on products, marks their positions on an adhesive film, and applies the film to protect the products during rechecking, reducing the need for manual inspection and potential new defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual rechecking is performed to confirm apparent defects, then defect detection accuracy is improved, but productivity decreases and new defects may be introduced
Solution Approach 1:
The system performs preliminary defect detection using AOI before manual rechecking, pre-marking apparent defect positions on the product surface. This preliminary action guides operators to only recheck marked positions, reducing the scope and time of manual inspection while maintaining detection accuracy.
Solution Approach 2:
The patent introduces an intermediary marking system that transfers defect position information from AOI detection to the physical product surface using adhesive film with magnetic particles. This intermediary medium bridges the gap between digital detection and manual verification, enabling efficient targeted rechecking without full manual inspection.
2Measurement precision
If manual sorting and transmission to rechecking is performed, then defect verification is achieved, but the process introduces new defects and increases operation time
Solution Approach 1:
Defect positions are pre-marked on the product surface during the initial AOI detection phase, before any manual handling occurs. This ensures that subsequent manual operations can be performed directly on marked positions without additional sorting, transmission, or repositioning that could cause new defects.
Solution Approach 2:
The system extracts only the essential defect position information and transfers it directly to the product surface via adhesive film marking, separating the detection function from the verification function. This eliminates the need for physical sorting and transmission of products to rechecking stations, reducing handling operations that could introduce new defects.
3Reliability
If operators manually inspect all apparent defects, then comprehensive quality control is achieved, but the process requires significant manpower and time
Solution Approach 1:
Instead of requiring operators to inspect entire product surfaces, the system applies local quality control by marking only the specific positions where defects are detected. Operators focus their attention and inspection efforts only on these localized marked areas, significantly reducing inspection time while maintaining comprehensive quality control at critical points.
Solution Approach 2:
The adhesive film with magnetic particles serves as an intermediary that visually communicates defect locations to operators. This mediator translates complex AOI detection data into simple,直观 visual markers that guide operators' attention, eliminating the need for manual image viewing and reducing rechecking time while ensuring reliable quality control.
Data Source
AI summary
A method for marking defects of products implemented in an electronic device is provided. The method includes obtaining at least one detection image of a product to be marked; recognizing a position and a type of at least one defect on the product according to the at least one detection image; transmit the position and the type of the at least one apparent defect to a robot arm; controlling the robot arm to mark the at least one defect on an adhesive film according to the position and the type of the at least one defect; and controlling a film coating unit to apply the adhesive film which is marked to the product.