Hybrid Component Pre-Inspection With Defect Removal Before Insertion
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Solution Overview
Problem
Defective components are supplied to hybrid irregular component insertion robots, leading to defective final products due to the inability to distinguish between acceptable and defective components before loading.
Innovation Solution
A component pre-inspection device with a camera, gantry robot, and control unit that automatically identifies and removes defective components by comparing real-time images with reference images, using a vacuum suction gripper to discharge them before loading into the robot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are arranged on the stick feeder regardless of defect status, then component supply continuity is maintained, but defective components are supplied to the insertion robot leading to defective final products
Solution Approach 1:
The inspection camera and gantry robot are positioned to perform defect detection and removal before components are loaded into the stick feeder. The camera captures images of components on the stick, the control unit analyzes them to identify defects, and the gantry robot removes defective components prior to the feeding process, ensuring only合格 components are supplied to the insertion robot
Solution Approach 2:
The defective components are extracted from the component batch using the gantry robot. The robot picks up identified defective components and discharges them to a separate location, separating them from the合格 components that continue to be supplied to the insertion robot, thus preventing defective components from entering the final product
2Reliability
If a pre-inspection device is added to identify and remove defective components, then final product quality is improved, but device complexity increases
Solution Approach 1:
The gantry robot serves multiple functions: it performs defect removal by picking up defective components, and it can also perform component placement by transferring合格 components to the insertion robot. The camera system provides both inspection functionality and image data for control decisions, reducing the need for separate dedicated components
Solution Approach 2:
The transparent portion of the stick feeder body acts as an intermediary that allows optical penetration. It enables the inspection camera to capture images of components on the stick through the transparent section, facilitating non-contact inspection without requiring physical manipulation or disassembly of the feeder structure
3Measurement precision
If real-time image comparison is performed to determine component acceptability, then defect detection accuracy is improved, but inspection time increases
Solution Approach 1:
Reference images of合格 components are stored in advance in the control unit's memory. During inspection, captured component images are immediately compared against these pre-stored reference images, enabling rapid defect identification without requiring complex real-time analysis or additional processing time
Solution Approach 2:
The inspection system replaces manual visual inspection with an automated optical inspection system. The camera captures images and the control unit automatically compares them against reference images using image processing algorithms, eliminating the time consumption and subjectivity of manual inspection while maintaining high accuracy
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
Reduces unnecessary inspection motions and increases production volume by pre-removing defective components, enhancing the quality and efficiency of the final product.
Implementation Method 1
a camera (140) configured to photograph a lower side of the components (C) being guided through the transfer unit (12) in real time
Implementation Method 2
a vacuum suction gripper configured to pick up the defective component, in which the gantry robot, upon receiving an operation signal transmitted from the control unit, may press the vacuum suction gripper closely against the defective component and suction the defective component
Data Source
AI summary
There is provided a component pre-inspection device for a hybrid irregular component insertion robot, installed on a transfer unit of a stick feeder type electronic component supplier that transfers components to a component pickup available position provided inside a hybrid irregular component insertion robot. The component pre-inspection device includes: a camera configured to photograph a lower side of the components being guided through the transfer unit in real time; a gantry robot configured to pick up and discharge defective components among the components guided by the transfer unit; and a control unit configured to determine whether the component is acceptable or defective by comparing a component image of the component photographed by the camera to a reference image of the component stored in a memory, and to operate the gantry robot when the component is determined to be defective.