Assembly Line Image Inspection for Accurate Defect Detection
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Solution Overview
Problem
Manual product inspection on assembly lines is labor-intensive, prone to human errors, and lacks accuracy due to the need for manual evaluation of products on conveyor belts, leading to faulty or missed inspections.
Innovation Solution
A product inspection method and system that uses image acquisition and processing to extract product images from a production line, apply inspection models (classifier, segmenter, or image template types) to identify defects, and determine product quality based on edge box positions and feature similarity, thereby automating the inspection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual product inspection is used on assembly lines, then labor flexibility is maintained, but inspection accuracy deteriorates due to human errors and fatigue
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated image processing system. Cameras capture product images on the assembly line, and computer algorithms automatically analyze defect information, replacing human inspectors entirely. This substitution eliminates human errors while maintaining continuous inspection capability.
Solution Approach 2:
The inspection system performs self-service by automatically capturing images, processing defect information, and generating inspection results without human intervention. The system serves itself by maintaining continuous operation on the assembly line, automatically adjusting to different products through image processing algorithms.
2Measurement precision
If automated image processing inspection is implemented, then inspection accuracy improves, but system complexity increases due to multiple processing steps
Solution Approach 1:
The patent creates a universal inspection system that handles multiple product types and defect categories through a single integrated platform. The image processing system performs various functions including defect detection, classification, and positioning using the same hardware and software framework, reducing the need for separate specialized systems.
Solution Approach 2:
The inspection system segments the complex inspection task into distinct processing stages: image acquisition, defect information extraction, defect classification, and result generation. This segmentation allows each module to be optimized independently while maintaining overall system manageability and reducing complexity through modular design.
3Reliability
If comprehensive defect detection is performed on all products, then quality control improves, but inspection time increases leading to reduced productivity
Solution Approach 1:
The patent implements continuous inspection by integrating image capture and processing into the ongoing assembly line flow. Products are inspected without stopping the production line, and the automated system processes images in real-time as products move along the conveyor, maintaining continuous useful action without interrupting productivity.
Solution Approach 2:
The system performs preliminary defect detection during the assembly process itself, identifying issues before products leave the production line. This preliminary action allows for immediate correction or sorting of defective products, ensuring quality control is built into the production flow rather than added as a separate post-processing step.
Data Source
AI summary
Disclosed are a product inspection method and device, producing system and a computer storage medium. The method comprises: conducting image acquisition on a product assembly line to obtain a production line image; extracting a product image including a product to be inspected from the production line image; extracting an inspection point image in a part inspection area in the product image; inputting the inspection point image into an inspection model to obtain an inspection result; and determining that the product to be inspected in the product image has defects under the condition that the inspection result meets any of the following conditions.