AI Image-Recognition System for AOI False Positive Reduction

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Solution Overview

Problem

Conventional automated optical inspection (AOI) systems often incorrectly classify qualified products as defective, lacking effective methods to detect and rectify such mistakes during large-scale manufacturing.

Innovation Solution

An AI-driven image-recognition system that includes modules for image-labeling, classification, generation, training, and evaluation, which processes check-point images from AOI systems to balance data distribution, filter erroneous labels, and retrain the AI model for improved recognition accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional AOI systems use strict judgement conditions to exclude unqualified products, then the reliability of defect detection is improved, but the manufacturing precision deteriorates due to increased false positives

Engineering Contradiction:
Improvedefect detection reliabilityVSAvoidproduct classification accuracy
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The system performs preliminary actions by collecting historical inspection data and artificially generating defective samples before the actual inspection process. This pre-preparation of diverse training data enables the AI model to learn from a wide range of scenarios, improving its ability to distinguish true defects from normal variations without requiring overly strict judgement conditions during production inspection.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system implements feedback mechanisms by continuously evaluating AI model performance using reserved test datasets and manually verified ground truth data. The model is retrained periodically with updated data, creating a closed-loop system that progressively improves detection accuracy while reducing false positives, thus balancing reliability and precision over time.

Inventive Principle:
Principle #23Feedback

2Reliability

If conventional AOI systems apply strict inspection criteria, then the reliability of identifying defective products is improved, but the productivity deteriorates due to increased manual verification requirements

Engineering Contradiction:
Improvedefect identification reliabilityVSAvoidinspection throughput
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The AI inspection system performs self-service by automatically learning from historical data and improving its own performance through continuous retraining. The system autonomously handles the inspection process without requiring constant manual intervention or verification, as the AI model progressively becomes more accurate in distinguishing defects from normal variations, thereby maintaining high reliability while preserving productivity.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

By pre-training the AI model with extensively curated and manually verified defect data before deployment, the system performs preliminary work that reduces the need for manual verification during actual production inspection. This advance preparation enables the model to handle a wide variety of defect scenarios autonomously, improving reliability without sacrificing throughput.

Inventive Principle:
Principle #10Preliminary action

3Loss of time

If the AI model is trained with imbalanced data distribution, then the training speed is improved, but the measurement precision deteriorates due to biased defect detection

Engineering Contradiction:
Improvemodel training timeVSAvoiddefect detection accuracy
Core Design Contradiction:
Loss of timeVSMeasurement precision

Solution Approach 1:

The system performs preliminary action by artificially generating defective samples and balancing the training data distribution before model training begins. This pre-balancing ensures that the AI model receives equitable exposure to different defect types during training, preventing bias toward majority classes and improving overall detection accuracy without significantly extending training time.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system applies parameter changes by adjusting the data distribution parameters to achieve balance across different defect categories. By modifying the composition of training datasets to ensure representative sampling of all defect types, the model learns more accurate decision boundaries for each category, improving measurement precision while maintaining efficient training through optimized data selection.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS11455490B2Image-recognition apparatus, image-recognition method, and non-transitory computer-readable storage medium thereof
Publication Date: 2022.09.27 WISTRON CORP
  • US11455490B2 patent drawing
  • US11455490B2 patent drawing
  • US11455490B2 patent drawing

AI summary

An image-recognition method is provided. The method includes the following steps: receiving a plurality of check-point images, and classifying the check-point images into a plurality of groups; classifying the check-point images in each group into a plurality of types to generate first structured data; balancing a number of the check-point images in each type of each group in the first structured data to generate second structured data, wherein the second structured data includes training-set data and testing-set data; training an artificial-intelligence (AI) model using the training-set data; and inputting the testing-set data into the AI model to obtain a model evaluation of the AI model.