Image Comparison System for Plating Inspection
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Solution Overview
Problem
The existing surface inspection devices for electroplating processes require human visual inspection to determine test results, which is prone to errors and unsustainable due to the shortage of skilled engineers.
Innovation Solution
An image comparison system that acquires surface state images of metal pieces after plating, matches them with historical images under similar test conditions, and displays them for comparative analysis, reducing the reliance on human judgment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection by operators is used to determine plating test results, then human judgment and experience can be applied, but the process becomes unsustainable due to shortage of skilled engineers and is prone to errors
Solution Approach 1:
The patent creates a digital copy of the reference image (stored in storage unit) that can be repeatedly used for comparison without degradation. This digital copy replaces the need for continuous human expert involvement, allowing sustainable automated inspection while maintaining consistent judgment criteria across multiple tests
Solution Approach 2:
The patent replaces the mechanical/human visual inspection system with an automated image processing system that uses computer algorithms to compare test images against reference images. This substitution eliminates dependence on skilled engineers while maintaining or improving determination accuracy
2Productivity
If automated image processing is implemented to replace human visual inspection, then productivity and sustainability are improved, but the ability to utilize accumulated expert knowledge for judgment is lost
Solution Approach 1:
The patent performs preliminary action by having skilled operators create and store reference images that encode their expert knowledge and judgment criteria. These reference images are created in advance under controlled conditions representing acceptable and unacceptable plating results, allowing the automated system to inherit expert knowledge without requiring ongoing human expertise
Solution Approach 2:
The patent copies the essence of expert judgment into the reference image database, where standardized images representing various plating conditions and their evaluations are stored. This copying mechanism preserves expert knowledge in a reusable format that the automated system can access and apply consistently
3Measurement precision
If strict matching of test conditions is required for image comparison, then accuracy of comparison is improved, but the complexity of condition matching and data management increases
Solution Approach 1:
The patent applies local quality by focusing comparison on specific regions of interest within the images rather than requiring complete matching of all test conditions. The system identifies and compares critical areas that matter most for plating quality assessment, reducing the burden of matching every parameter perfectly while maintaining high comparison accuracy
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
An image comparison system (300) comprises: an acquisition unit (111) that acquires a surface state image of a metal piece that shows the result of a plating test; a condition acquisition unit (113) that acquires test conditions for the plating test with respect to a newly acquired surface state image; a storage unit (120) that stores surface state images and test conditions; an extraction unit (114) that extracts, from the storage unit (120), another surface state image for which at least some of the test conditions match the test conditions of the newly acquired surface state image; and a display control unit (115) that causes the newly acquired surface state image and the other surface state image extracted by the extraction unit (114) to be displayed on a display unit (160) in a comparable manner.