Image Processing for Component Protrusion Detection in Mounting Systems
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Solution Overview
Problem
Existing mounting devices lack a reliable method for accurately recognizing and positioning components with protruding sections, such as leaded electronic components, during the mounting process, as they do not effectively consider the protruding sections' shapes and positions when inserting them into board holes.
Innovation Solution
An image processing device is employed that uses side lighting and vertical lighting to capture images of components, detecting the shape, positions, and number of protruding sections, and generates a component model to guide the mounting process, allowing for accurate recognition and insertion without requiring special lighting or imaging for the distal end portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional imaging methods are used to pick up components, then the mounting process can be performed, but the protruding sections cannot be accurately detected and positioned
Solution Approach 1:
The imaging system is divided into two independent imaging sections: one for imaging the main body of the component and another for imaging the protruding sections. Each imaging section has dedicated lighting and detection functions, allowing accurate detection of protruding sections without requiring a completely new complex imaging system. The segmentation enables specialized detection for each component part.
Solution Approach 2:
A projection optical system is introduced as an intermediary between the object optical system and the imaging section for protruding sections. This projection optical system projects the protruding sections onto a plane where they can be imaged by the imaging section, enabling accurate detection of three-dimensional protruding structures using a two-dimensional imaging sensor without requiring complex 3D imaging capabilities.
2Reliability
If special lighting sections or imaging sections are used to focus on distal end portions, then detection reliability improves, but device complexity increases
Solution Approach 1:
The lighting system is segmented into a first lighting section for the main body and a second lighting section for the protruding sections. Each lighting section provides optimized illumination for its specific target, improving detection reliability without requiring a single complex lighting system to handle all detection needs.
Solution Approach 2:
The projection optical system serves multiple functions: it projects the protruding sections for imaging, enables the use of standard two-dimensional imaging sensors for three-dimensional object detection, and works seamlessly with the existing main body imaging system. This multi-functionality reduces the need for entirely new specialized components.
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 approach enables a more reliable and simpler mounting process for components with protruding sections by accurately detecting and positioning them, reducing errors and increasing efficiency in component placement.
Implementation Method 1
acquire a captured image obtained by imaging the component by side lighting and/or vertical lighting of an imaging unit including a lighting section and an imaging section, the lighting section being configured to turn on the side lighting for irradiating the component with light from side and the vertical lighting for irradiating the component with light from below
Data Source
AI summary
An image processing device, for use in a mounting device, detects a shape of the main body, positions of protruding sections, a number of the protruding sections, and a distal end portion of the protruding section of the mounting device from a captured image of the protruding section radiated with light from side with respect to the component and the main body radiated with light from below with respect to the component. The image processing device acquires information of the insertion sections, and generates a component model including a contour shape model including the shape and the direction of the main body and a protruding section model including the positions and the number of the protruding sections, and a feature of the distal end portion of the protruding section.