Automated Optical Inspection of Laser-Cut Chip Card Recesses
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Solution Overview
Problem
Errors in the alignment and placement of electronic circuits within chip cards can result in non-functional or short-lived functionality due to issues with the production process, particularly in the creation of recesses using laser cutting for accommodating chip modules in chip cards.
Innovation Solution
An inspection device utilizing an illumination source, image camera, and processor to determine the course of the laser cutting edge by capturing images with increased light intensity, allowing for automated verification of semi-finished chip cards, which enhances the detection and processing of the laser cutting edge as a security feature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated verification is implemented to detect alignment errors, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical verification system using a camera and image processing algorithms. The system captures images of the laser cutting edge and uses automated image analysis to detect alignment errors, substituting mechanical/optical measurement with computational analysis to achieve precise verification without complex mechanical measurement devices
Solution Approach 2:
The patent creates a digital copy (image) of the physical laser cutting edge and performs verification on this copy through image processing. By capturing the cutting edge geometry as an image and analyzing it computationally, the system avoids the need for complex physical measurement apparatus while maintaining high verification precision
2Productivity
If manual inspection is used to verify alignment, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The verification system performs self-verification through automated image capture and processing. The camera automatically captures images of the laser cutting edge, and the integrated image processing algorithms automatically analyze alignment accuracy without requiring external inspection equipment or manual measurement tools, enabling rapid self-verification that improves productivity
Solution Approach 2:
The patent replaces slow manual inspection processes with automated optical capture and computational analysis. The system uses a camera to rapidly capture images and employs image processing algorithms to instantly analyze alignment, replacing the time-consuming manual measurement process with fast automated optical-electrical-computational verification
3Measurement precision
If traditional inspection methods are used, then device complexity is minimized, but measurement precision of laser cutting edge deteriorates
Solution Approach 1:
The patent replaces imprecise manual measurement methods with automated optical imaging and digital image processing. The camera captures high-resolution images of the laser cutting edge, and image processing algorithms automatically detect the cutting edge position and analyze its geometry with high precision, substituting manual measurement with optical-electrical-computational analysis to achieve superior measurement accuracy
Solution Approach 2:
The patent creates a high-resolution digital copy of the laser cutting edge through image capture and uses image processing to extract precise geometric information. By analyzing the digital image copy rather than directly measuring the physical feature, the system achieves high measurement precision while avoiding the limitations of manual measurement tools
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables efficient automated verification of chip card semi-finished products, reducing errors and ensuring proper alignment and placement of electronic circuits, thereby maintaining chip card functionality under normal usage conditions.
Implementation Method 1
an illumination source, which is designed to illuminate the semi-finished product with light of a predetermined wavelength
Implementation Method 2
an image camera, which is designed to capture an image of the illuminated semi-finished product
Implementation Method 3
due to optical effects that may be similar to the optical effects that occur with optical lenses, prisms or light guides, the laser cutting edge appears as an area or the spatial structure of increased intensity
Data Source
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AI summary
The invention relates to an inspection device (100) for verifying a semi-finished product (101) for manufacturing a chip card with a recess bounded by a laser cutting edge (103a) for receiving an electronic circuit (104) comprising: a light source (105) configured to illuminate the semi-finished product (101) with light of a predetermined wavelength; a camera (107) configured to capture an image of the illuminated semi-finished product (101) with the recess bounded by the laser cutting edge (103a); and a processor (109) configured to detect in the captured image a circumferential area with a light intensity greater than the light intensity of an area in the captured image outside the circumferential area in order to determine the path of the laser cutting edge (103a) and to verify the semi-finished product (101) based on the path of the laser cutting edge (103a).