Modular Foil Inspection System for Surface Morphology
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Solution Overview
Problem
Variations in environmental, equipment, and raw material factors lead to inconsistencies in the micro-roughing structure of electro-forming aluminum foil, affecting the performance of aluminum electrolytic capacitors, necessitating a real-time automated optical inspection system for in-line monitoring.
Innovation Solution
A surface inspection system comprising a box with modular camera devices and light sources integrated into an automatic production line, utilizing pre-trained defect recognition models to analyze the surface morphology of electro-forming aluminum foil for defects and profile image generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated optical inspection system is implemented, then measurement precision of surface morphology is improved, but device complexity increases
Solution Approach 1:
The inspection system is divided into multiple independent modules including light source module, camera module, and processing module, each performing specific functions. This segmentation allows for precise surface morphology measurement while maintaining manageable system complexity through modular architecture.
Solution Approach 2:
A bridge interface board serves as an intermediary component that connects and coordinates between different inspection modules and the control system. This mediator simplifies the overall system complexity by providing a centralized communication and control interface.
2Productivity
If in-line inspection is implemented, then productivity is improved, but measurement precision may deteriorate due to production line environment
Solution Approach 1:
The inspection system performs preliminary capture of surface morphology data during the production process before defects can propagate. By capturing images at the point of formation, the system maintains measurement precision while enabling continuous production flow.
Solution Approach 2:
The system replaces complex mechanical contact measurement methods with optical field-based measurement. This substitution enables non-contact, high-speed inspection that maintains precision while improving productivity by not interrupting the production line.
3Measurement precision
If multiple camera devices and light sources are used, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The bridge interface board is designed as a universal platform that can accommodate multiple camera devices and light sources with different specifications. This multi-functional design enables precise multi-angle surface inspection while simplifying assembly through standardized interfaces and mounting structures.
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
Enables real-time, in-line inspection of the surface morphology of electro-forming aluminum foil, ensuring consistent quality and reducing undesirable variations in capacitor performance.
Implementation Method 1
a first light source, being disposed in the box so as to be adjacent to a first side of the box... a second light source, being disposed in the box so as to be adjacent to a second side of the box
Implementation Method 2
a first modular camera device having a first camera, and a second modular camera device having a second camera... such that the first lens faces to a first surface of the foil article in the box; and wherein the second modular camera device comprises a second housing case and at least one second camera accommodated in the second housing case, and the at least one second camera being exposed out of the second housing case by a second lens thereof, such that the second lens faces to a second surface of the foil article in the box
Data Source
AI summary
A surface inspection system for foil article is disclosed. The surface inspection system comprises a box having a top long narrow opening and a bottom long narrow opening, a bridge interface, a first light source, a second light source, a first modular camera device having a first camera, and a second modular camera device having a second camera. In which, the first light source, the second light source, the first modular camera device, and the second modular camera device all accommodated in the box, and are coupled to a control box through the bridge interface. Particularly, this surface inspection system is allowed to be integrated in an automatic production line of a foil article like electro-forming aluminum foil (also called electronic aluminum foil), so as to achieve an in-line inspection of the surface morphology of the electro-forming aluminum foil.