AOI Optical Parameter Feedback for Stable Inspection Accuracy

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Solution Overview

Problem

Current optical parameter setting in automatic optical inspection systems is prone to misjudgment and variability among experts, leading to unstable quality control and reduced production efficiency due to manual adjustments.

Innovation Solution

An automated method and system that includes a camera module, error calculation module, optical parameter recommendation module, and automatic setting module to automatically set optical parameters by calculating error values and converging on an optimal parameter set using an optimized error function, reducing reliance on human expertise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If optical parameters are manually adjusted by experts based on experience, then the detection accuracy may be improved through expert knowledge, but the quality control becomes unstable due to variability among different experts and the process becomes time-consuming

Engineering Contradiction:

Improvedetection accuracyVSAvoidmanual adjustment time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs self-adjustment of optical parameters through automated feedback mechanisms. The inspection system automatically captures images, calculates quality metrics, compares them against standards, and adjusts parameters without human intervention, enabling the system to service itself and eliminate manual adjustment time while maintaining consistent quality

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical adjustment process with an automated control system. Instead of experts physically adjusting optical parameters, the system uses automated image capture, error calculation, and parameter adjustment mechanisms to substitute human operations with mechanical and computational processes, thereby reducing time loss and eliminating human variability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If optical parameters are manually adjusted by experts based on experience, then initial detection capability is achieved, but misjudgment risks increase and quality control stability deteriorates due to subjectivity

Engineering Contradiction:

Improvequality control stabilityVSAvoiddetection accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system implements continuous feedback loops where inspection results are automatically fed back to adjust optical parameters. The system captures images, calculates quality metrics, compares them with standard values, and uses this feedback to automatically adjust parameters, ensuring consistent and reliable quality control without subjective human judgment

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system automatically changes optical parameters based on calculated errors and quality metrics. Instead of relying on expert judgment to determine parameter values, the system dynamically adjusts parameters such as exposure time, gain, and focus based on real-time feedback from the inspection process, ensuring objective and repeatable results

Inventive Principle:

Principle #35Parameter changes

3Productivity

If manual adjustment of optical parameters is performed, then flexibility in adapting to different inspection scenarios is maintained, but production speed and efficiency are reduced due to the time-consuming nature of manual processes

Engineering Contradiction:

Improveproduction speedVSAvoidoperational simplicity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system automatically performs all optical parameter adjustments without requiring operator intervention. The inspection system captures images, evaluates quality, and self-adjusts parameters, making the system self-sufficient and eliminating the time-consuming manual operations that reduce production speed while maintaining ease of operation through automation

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11788972B2Method of automatically setting optical parameters and automated optical inspection system using the same

Publication Date: 2023.10.17 IND TECH RES INST

AI summary

A method of automatically setting optical parameters, using Automatic Optical Inspection (AOI) System, the method includes the following steps. Firstly, a recommended object image is obtained when the AOI system is set under a first recommended optical parameter set. Then, a computation is performed on an object standard picture and a recommended object image to obtain a recommended error value between the object standard picture and the recommended object image according to an optimized error function. Then, whether the recommended error value converges is determined. Then, when the recommended error value does not converge, a computation is performed to obtain a second recommended optical parameter set according to the recommended error value and the first recommended optical parameter set. Then when the recommended error value converges, the first recommended optical parameter set is decided as an optimal optical parameter set of the AOI system.