Workpiece Design Image Compensation via Registration Hole Slope Analysis
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Solution Overview
Problem
In various industries, such as the production of print circuit boards (PCBs), workpieces often experience expansion or shrinkage due to moisture absorption or desorption, leading to distortion and affecting the quality of the final product if a design image is directly mapped onto them without compensation.
Innovation Solution
A method and system that involve obtaining a real image of the workpiece with registration holes, calculating slope values, determining interpolation points, and using control points to compensate the design image, generating a mapping image that accounts for the workpiece's actual dimensions, thereby ensuring accurate mapping despite expansion or shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an original design image is directly mapped onto the workpiece, then the mapping process is simple and fast, but the quality and accuracy of the workpiece deteriorate due to expansion or shrinkage distortion
Solution Approach 1:
The patent applies preliminary action by performing image compensation before the mapping process. The system calculates slope values for registration holes, determines interpolation points, and pre-adjusts the design image to account for expected expansion or shrinkage. This preliminary compensation ensures that when the image is finally mapped onto the physical workpiece, the distortion is already corrected, achieving high mapping accuracy without adding complexity to the actual mapping operation.
Solution Approach 2:
The patent replaces physical measurement and adjustment mechanisms with computational methods. Instead of using mechanical tools to measure and adjust the workpiece or mapping process, the system uses image processing algorithms to calculate slope values, generate interpolation points, and computationally compensate the design image. This substitution of mechanical systems with computational approaches maintains simplicity while achieving high precision.
2Manufacturing precision
If compensation processing is performed to account for workpiece expansion or shrinkage, then mapping accuracy is improved, but processing time increases
Solution Approach 1:
The patent applies segmentation by dividing the compensation processing into distinct modular steps: obtaining the real image, calculating slope values for registration holes, determining interpolation points based on slope values, and generating the compensated design image. This segmentation allows each step to be optimized independently and enables parallel processing where applicable, reducing overall processing time while maintaining high mapping accuracy through systematic compensation.
3Productivity
If high-density layout with small trace widths is used on PCB, then circuit integration is improved, but the workpiece becomes more sensitive to expansion or shrinkage distortion
Solution Approach 1:
The patent applies local quality by calculating individual slope values for each registration hole and determining interpolation points specifically for each local region of the workpiece. Rather than applying a uniform compensation across the entire image, the system adjusts each local area based on its specific distortion characteristics, which is particularly important for high-density PCB layouts where even minor local distortions can cause trace misalignment or manufacturing defects.
Data Source
AI summary
A method for compensating a design image of a workpiece and a system for processing the design image of the workpiece are disclosed. The method includes the following steps. Obtaining a real image of the workpiece, with the real image having registration holes. Calculating a slope value for each of the registration holes. Determining an amount of interpolation points between each two neighboring registration holes of the registration holes according to the slope value corresponding to each of the registration holes. Obtaining positions of control points in blocks formed by the registration holes. Compensating the design image of the workpiece according to positions of the registration holes, positions of the plurality of interpolation points and the positions of the control points for generating a mapping image. Outputting the mapping image adapted to be mapped onto the workpiece. The system, together with the method, will be introduced.