In the electronics/PCBA industry, the detection of three-proof coating coverage and foreign objects is a crucial step in ensuring product quality. WeLinkirt provides an efficient detection solution for a leading electronics/PCBA manufacturer with advanced AI vision technology.
User Scenario: A leading electronics/PCBA manufacturer needs to detect the three-proof coating coverage on PCBA boards and the presence of foreign objects in the three-proof coating process of its production line. The products are various PCBA boards, and the detection objects are the evenness of the three-proof coating, the presence of uncoated areas, and foreign objects on the boards, such as dust and welding slag.
Pain Points: The traditional manual detection method has many problems. First, the miss rate is relatively high, about 3%, which causes some unqualified products to enter the market and affects the product reputation. Second, the false alarm rate reaches 20%, increasing the unnecessary re-inspection workload and significantly raising the quality inspection cost. In addition, the manual detection is inefficient, and the changeover time is long. Each changeover takes 30 minutes, seriously affecting the production efficiency of the production line. Moreover, it is difficult for manual detection to ensure 100% defect coverage, which cannot meet the strict quality compliance requirements.
Technical Principle
WeLinkirt uses advanced AI algorithms and imaging technologies to solve these problems. In terms of algorithms, the visual basic model in the DaoAI AI AOI software system is used. Through APDT positive sample/few-shot learning (only 1 - 20 good samples are needed), the normal features of the product can be quickly learned. This few-shot learning method effectively reduces the workload of sample collection and annotation and improves the generalization ability of the model. In terms of imaging, the DaoAI 2D / 3D AI AOI device uses a self-developed 3D camera for three-dimensional shape reconstruction. For the three-proof coating coverage, 3D imaging can clearly capture the thickness and evenness of the paint layer and detect hidden uncoated areas. For foreign object detection, 3D imaging can accurately identify tiny foreign objects because it can provide the three-dimensional information of the object, avoiding possible misjudgments in 2D imaging.
- The feature recognition ability of the visual basic model enables the system to quickly and accurately identify the normal and abnormal features of the product.
- The APDT positive sample/few-shot learning method reduces the sample requirements and improves the model training efficiency.
- The three-dimensional shape reconstruction technology of the self-developed 3D camera provides more comprehensive detection information and improves the detection accuracy.
- The semantic false alarm filtering function can effectively reduce false alarms and improve the reliability of detection.
WeLinkirt Solution and Product Introduction
WeLinkirt provides a combined solution of the DaoAI AI AOI software system and the DaoAI 2D / 3D AI AOI device. The DaoAI AI AOI software system has powerful feature recognition capabilities. Only 5 minutes are needed to complete 0-code automatic programming for a good product, greatly shortening the programming time. Its APDT positive sample/few-shot learning function can complete model training with only 1 - 20 good samples, meeting the rapid changeover requirements of different products. At the same time, the semantic false alarm filtering function can effectively reduce the false alarm rate. The DaoAI 2D / 3D AI AOI device uses a self-developed 3D camera, which can perform three-dimensional shape reconstruction and detect hidden solder joints, coplanarity, and micron-level shapes. It has high-precision detection capabilities for three-proof coating coverage and foreign object detection. In terms of implementation, the device is installed after the three-proof coating process of the production line. The software system is integrated with the device to detect PCBA boards in real-time and feed back the detection results to the production line.
WeLinkirt's AI vision solution provides an efficient and accurate detection method for the three-proof coating coverage and foreign object detection in the electronics/PCBA industry.
Quantitative Results: By applying WeLinkirt's solution, the detection effect of the manufacturer has been significantly improved. The detection rate has reached 98%, and the miss rate has been reduced to 2%, effectively reducing the risk of unqualified products entering the market. The false alarm rate has been reduced to 5%, greatly reducing the unnecessary re-inspection workload and reducing the quality inspection cost by 40%. The changeover time has been shortened from the original 30 minutes to 5 minutes, improving the production efficiency of the production line. At the same time, the defect coverage rate is close to 100%, meeting the strict quality compliance requirements.