Component Recognition System for Mounting Machines Using Patterned Light
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Solution Overview
Problem
Current component mounting machines require prolonged processing times for capturing three-dimensional images of components due to the need for slow movement and low-speed scanning, leading to decreased productivity and accuracy in defect inspection, particularly in the height direction.
Innovation Solution
A component recognizing system that includes a camera imaging the component from below, a light pattern projecting device projecting patterns in directions different from the camera, and an image processing device capable of recognizing both two-dimensional and three-dimensional shapes, allowing for mode switching to optimize processing time and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If one-dimensional scanning using a laser beam is repeatedly performed to capture three-dimensional images, then measurement precision in the height direction is improved, but productivity deteriorates due to the need for slow component movement
Solution Approach 1:
The patent transitions from one-dimensional laser scanning to two-dimensional imaging by projecting light patterns (such as stripe patterns or grid patterns) onto the component surface and capturing the deformed patterns with a camera. This dimensional change allows simultaneous acquisition of height information across the entire component surface in a single shot, eliminating the need for slow sequential scanning while maintaining measurement precision.
Solution Approach 2:
The patent replaces the mechanical scanning system (moving laser beam point-by-point or line-by-line) with an optical field-based system that uses light pattern projection and image processing. The light field carries three-dimensional shape information directly, eliminating mechanical movement and enabling rapid capture of height data without compromising measurement accuracy.
2Measurement precision
If component movement speed is reduced to stabilize movement during scanning, then three-dimensional image capture accuracy is improved, but the time required for capturing images increases
Solution Approach 1:
By projecting two-dimensional light patterns onto the component and capturing them with a camera, the system obtains three-dimensional shape information in a single static shot. This eliminates the temporal dimension of sequential scanning, allowing high-precision measurement without requiring slow component movement or extended capture time.
Solution Approach 2:
The light pattern is projected onto the component surface before any movement occurs, and the camera captures the entire pattern deformation simultaneously. This preliminary optical setup ensures that height information is frozen and recorded in a single moment, eliminating the need for slow movement to maintain accuracy during the measurement process.
3Measurement precision
If the component is temporarily stopped in front of the scanning area to stabilize movement speed, then measurement accuracy is improved, but productivity deteriorates due to increased processing time
Solution Approach 1:
The patent replaces the mechanical stop-and-scan approach with an optical field-based measurement system that captures three-dimensional information in a single static image. This eliminates the need to stop the component for measurement, as the optical system can acquire height data while the component is stationary or even moving at normal speed, thereby maintaining both accuracy and productivity.
Solution Approach 2:
By using two-dimensional light pattern projection and camera imaging, the system transforms the measurement process from a time-consuming sequential scan into an instantaneous parallel capture. This dimensional transformation allows the component to remain in normal operation without temporary stops, preserving productivity while achieving high measurement accuracy through optical field analysis.
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 configuration enables faster recognition of three-dimensional shapes without the need for slow component movement, improving productivity and accuracy in defect inspection, while also allowing for efficient processing of components with simple shapes by switching to two-dimensional mode.
Implementation Method 1
a light pattern projecting device that projects a predetermined light pattern onto the component sucked by the suction nozzle in a direction different from an imaging direction of the camera
Implementation Method 2
a camera that images the component sucked by the suction nozzle from below
Data Source
Figure 1
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AI summary
A camera 17 by which a component 16 sucked by a suction nozzle 15 in a component mounting machine is imaged from below is installed so as to face upward. Two light pattern projecting devices 21 and 22 for projecting a predetermined light pattern onto the component 16 in a direction different from an imaging direction of the camera 17 are respectively installed in both ends of the camera 17. The light pattern projecting devices 21 and 22 project the light pattern onto the component 16, an image captured by the camera 17 is processed, and the light pattern on a surface of the component 17 is recognized so as to recognize a three-dimensional shape (height) of the component 16 when viewed from below.