Loose Component Supply Imaging for Accurate Replenishment Timing
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Solution Overview
Problem
Existing component supply systems face challenges in accurately determining the timing for replenishing components on a stage, leading to inefficiencies and a need for improved practicality in component estimation and replenishment.
Innovation Solution
A component supply system that includes a stage with scattered components, a replenishing device, and an imaging device to capture and compare pre- and post-replenishment imaging data, allowing for precise determination of when to replenish components based on brightness and color differences in the captured images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing component supply systems use conventional estimation methods to determine component quantity on stage, then the system can operate with basic replenishment capability, but the determination method is complex and accuracy is insufficient
Solution Approach 1:
The patent creates a virtual copy of the stage surface by generating a background image that represents the empty stage state. This background image serves as a reference model that is subtracted from current stage images to extract component information, eliminating the need for complex thresholding and segmentation algorithms while improving measurement accuracy
Solution Approach 2:
The patent extracts only the essential information needed for component detection by subtracting the background image from the current stage image. This extraction method isolates component pixels from the complex stage environment, simplifying the determination process while enhancing detection accuracy
2Ease of operation
If the system uses simple imaging comparison to determine replenishment timing, then the operation is easy, but the accuracy of component presence detection is insufficient
Solution Approach 1:
The system creates an accurate digital copy of the empty stage state as a background image, which serves as a precise reference for comparison. This copying approach enables simple subtraction operations that are both easy to implement and highly accurate in detecting component presence and quantity
Solution Approach 2:
The patent replaces complex mechanical or manual inspection methods with optical imaging and digital image processing. The imaging device captures stage states, and digital subtraction algorithms automatically determine component presence, providing both operational simplicity and high detection accuracy
3Measurement precision
If the system captures detailed imaging data of the stage, then the accuracy of component detection is improved, but the processing time and system complexity increase
Solution Approach 1:
The system performs preliminary action by capturing and storing a background image of the empty stage state before components are placed. This pre-captured reference image is ready for immediate subtraction from subsequent stage images, enabling rapid component detection without requiring complex real-time processing
Solution Approach 2:
By creating a static background copy of the stage and using simple pixel-wise subtraction, the system achieves accurate component detection with minimal processing time. The copying approach transforms a potentially complex recognition problem into a simple arithmetic operation that can be performed rapidly
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 simplifies the determination of replenishment timing, enhances the accuracy of component presence detection, and improves the practicality of the component supply system by ensuring appropriate and timely replenishment.
Implementation Method 1
an imaging device (84) configured to image the stage
Data Source
AI summary
A loose component supply device in which a stage on which components are scattered is imaged by an imaging device and the area of the stage imaged by the imaging device is divided into 20×20 blocks. A difference value between first imaging data that is imaging data of the stage without any components loaded and second imaging data that is imaging data of the stage after component supply has been started and components replenished onto the stage is calculated for each block. If the difference value is equal to or greater than a threshold value, it is determined that a component is present in the block, and if it is determined that the quantity of blocks for which it is determined that a component is present is equal to or less than a set quantity, components are replenished to the stage.