3D AI AOI Equipment Achieves Remarkable Results in Detecting Pin Coplanarity

In the electronics/PCBA industry, the detection of pin/connector coplanarity is crucial. As Youkece's high-precision flash measuring instrument makes breakthroughs in industrial vision quality inspection, WeLinkirt's 3D AI AOI equipment also brings a new detection solution to the industry.

User Scenario: A leading electronics manufacturing company needs to detect the coplanarity of pins/connectors after the assembly process of pins/connectors on its PCBA production line. As important connecting components in electronic devices, the coplanarity of pins/connectors directly affects the performance and stability of electronic products.

Pain Points: Traditional detection methods have many problems. The missed detection rate is relatively high, reaching about 3%, which causes some defective products to flow into subsequent processes, increasing product rework and after-sales costs. The false alarm rate is also not to be underestimated, about 15%. This leads to a large number of qualified products being misjudged and requiring re-inspection, wasting a lot of manpower and time. In addition, the change-over time is long. It takes about 30 minutes to change the product model each time, seriously affecting the production efficiency of the production line. The news that Youkece's high-precision flash measuring instrument has achieved a measurement accuracy of less than 1 micron and tripled the efficiency highlights the deficiencies of the company's current detection methods in terms of accuracy and efficiency.

Technical Principle

WeLinkirt's 3D AI AOI equipment uses a self-developed 3D camera for image acquisition, based on the principle of structured light projection and triangulation. The equipment projects a specific structured light pattern onto the measured object, captures the light pattern reflected from the object surface through the camera, and calculates the three-dimensional coordinates of each point on the object surface using the triangulation principle, thus realizing 3D shape reconstruction and generating point cloud data.

• This method can accurately obtain the 3D shape information of pins/connectors, and can clearly detect defects in 2D optical blind areas such as hidden solder joints, coplanarity, micron-level morphology, and air holes. Since 3D data contains the height information of the object, compared with 2D images, it can more comprehensively reflect the real shape of the object, avoiding the missed detection problem caused by the lack of height information in 2D detection.
• At the same time, the equipment uses 2D-3D fusion technology, which combines the texture information of 2D images and the depth information of 3D point clouds to further improve the detection accuracy. By extracting and matching features from 2D images and 3D point clouds, it can better identify various defects, and machine learning algorithms can be used to classify and discriminate different types of defects.

WeLinkirt Solution and Product

WeLinkirt provides a complete detection solution for the company with the 3D AI AOI equipment as the core. The equipment has high-precision 3D imaging capabilities and advanced 2D-3D fusion detection technology, which can quickly and accurately detect the coplanarity of pins/connectors and other potential defects.

The 3D camera of the equipment can quickly obtain the 3D point cloud data of pins/connectors. Through the 3D shape reconstruction algorithm, the point cloud data is converted into an intuitive 3D model, which is convenient for inspectors to observe and analyze.

The supporting DaoAI AI AOI software system uses the feature recognition technology of the visual basic model. With only 1-20 good samples, it can realize zero-code automatic programming in 5 minutes, greatly shortening the programming time and difficulty. At the same time, the APDT positive sample/few-sample learning and semantic false alarm filtering functions of the software can effectively reduce the false alarm rate and improve the detection efficiency.

Quantitative Results: After using WeLinkirt's 3D AI AOI equipment, the detection rate of pin/connector coplanarity of the company has increased to 99.2%, and the missed detection rate has been reduced to < 0.8%, effectively reducing the situation of defective products flowing into subsequent processes. The false alarm rate has been reduced by -70%, from the original 15% to 4.5%, greatly reducing the re-inspection workload. The change-over time has been shortened from the original 30 minutes to 5 minutes, improving the production efficiency of the production line.