Touchless Optical Inspection Interface for Component Carrier Arrays

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Solution Overview

Problem

The increasing miniaturization and complexity of component carriers with multiple electronic components pose challenges in heat removal and mechanical robustness, while conventional optical inspection by human operators is cumbersome and prone to damage.

Innovation Solution

A method and apparatus for optical inspection of component carriers that allows quality classification without mandatory manual handling, using a display and user interface for human operators to assess arrays electronically, with optional manual handling and automated defect proposals assisted by artificial intelligence.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional optical inspection by human operators is performed with mandatory manual handling, then inspection thoroughness can be maintained, but damage risk to component carriers increases and inspection efficiency decreases

Engineering Contradiction:

Improveinspection reliabilityVSAvoiddamage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent displays images of component carriers on a screen to the human operator, creating a visual copy that replaces direct physical contact. The operator inspects the displayed images and inputs quality judgments without touching the actual component carriers, thus eliminating damage risk while maintaining inspection thoroughness through high-resolution visual reproduction

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical handling system with an optical-digital system. Instead of physically manipulating component carriers, the system uses cameras to capture images, displays them on screens, and allows operators to interact through digital interfaces, substituting mechanical contact with optical and electronic processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional optical inspection by human operators is performed with mandatory manual handling, then quality judgment can be made, but inspection efficiency and productivity decrease

Engineering Contradiction:

Improvequality classification accuracyVSAvoidinspection efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

By displaying images of multiple component carriers simultaneously on a screen, the system allows operators to inspect multiple items in parallel rather than sequentially handling each one. This visual copying approach maintains quality judgment accuracy while significantly improving inspection throughput and efficiency

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The system performs preliminary actions by capturing images, processing them, and displaying them to the operator before the inspection decision is required. This preparation of visual information in advance allows the operator to focus solely on quality judgment without the time-consuming actions of picking, positioning, and illuminating each component carrier

Inventive Principle:

Principle #10Preliminary action

3Productivity

If automated inspection systems are used, then productivity increases and damage risk decreases, but measurement precision and detection capability for complex defects may be reduced

Engineering Contradiction:

Improveinspection throughputVSAvoiddefect detection capability

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent introduces an intermediary system consisting of cameras, image processing algorithms, and display equipment between the component carriers and the human operator. This intermediary captures and enhances visual information, presenting it in an optimized format that leverages both automated capture speed and human pattern recognition capabilities for superior defect detection

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces manual inspection mechanics with automated optical capture and digital display, enabling high-speed image acquisition and simultaneous presentation of multiple component carriers while maintaining high measurement precision through controlled lighting, focused imaging, and enhanced display resolution

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11935221B2User interface for judgment concerning quality classification of displayed arrays of component carriers

Publication Date: 2024.03.19 AT&S (CHONGQING) CO LTD

AI summary

A method of processing component carriers includes supplying a plurality of arrays, each comprising a plurality of component carriers, to a human operator for optical inspection, displaying a respective array on a display, and providing a user interface enabling the human operator to input a judgment concerning a quality classification of a displayed array without a mandatory manual handling of the array by the human operator.