In the electronics manufacturing industry, the quality of PCBA assembly directly affects the performance and reliability of products. WeLinkirt provides an effective solution to the problems of missing components and incorrect connector installation in PCBA assembly with advanced AI vision technology.
User Scenario: A leading electronics/PCBA manufacturer's PCBA assembly line, which mainly produces printed circuit board assemblies for various electronic products. In the assembly process, it is necessary to detect missing components on the PCBA and incorrect installation of connectors to ensure that the quality of each PCBA meets the standards. The detection objects include various surface - mount components, through - hole components, and different types of connectors.
Pain Points: The manufacturer faces multiple dilemmas. Firstly, due to the high product yield, defective samples are inherently scarce. Moreover, considering data confidentiality, it is difficult to obtain a large number of defective samples for model training, resulting in poor performance of traditional machine - learning methods during the cold start of detection. Secondly, manual inspection has problems of missed detection and false alarms. The missed detection rate is about 5%, and the false alarm rate is as high as 30%, which not only increases labor costs but also affects production efficiency. In addition, when changing the production line model, traditional detection equipment needs to be reprogrammed and debugged, and the model - changing time can be as long as several hours, seriously affecting the flexibility of production.
Technical Principles
WeLinkirt uses advanced AI algorithms and imaging technologies to solve the above problems. In terms of algorithms, it utilizes the feature - recognition ability of the visual basic model to quickly identify the features of components on the PCBA. The APDT positive - sample/few - sample learning algorithm can achieve efficient model training with only 1 - 20 good samples, effectively solving the problem of scarce defective samples. In terms of imaging, the self - developed 3D camera combined with 3D morphology reconstruction technology can obtain the 3D information of the PCBA. It can not only detect surface missing components and incorrect installations but also detect deep - seated defects such as hidden solder joints, coplanarity, and micron - level morphology. This technology is effective because it can comprehensively analyze the PCBA from multiple dimensions, greatly improving the accuracy of detection.
- Visual basic model: By learning from a large number of good samples, it extracts the features of components to provide a basis for subsequent detection.
- APDT positive - sample/few - sample learning algorithm: It uses a small amount of good - sample data for model training, reducing the dependence on defective samples.
- 3D camera and 3D morphology reconstruction: It obtains the 3D information of the PCBA to detect hidden defects.
- Semantic false - alarm filtering: It conducts semantic analysis on the detection results to filter out false - alarm information.
WeLinkirt Solutions and Products
WeLinkirt provides the DaoAI AI AOI software system and the DaoAI 2D / 3D AI AOI equipment. The DaoAI AI AOI software system has a powerful feature - recognition ability. It can achieve zero - code automatic programming for a good sample in 5 minutes, greatly shortening the programming time. Its APDT positive - sample/few - sample learning function can perform efficient model training with few samples. At the same time, the semantic false - alarm filtering function can effectively reduce the false - alarm rate. The DaoAI 2D / 3D AI AOI equipment uses a self - developed 3D camera and 3D morphology reconstruction technology to detect defects such as hidden solder joints, coplanarity, and micron - level morphology. In the implementation process, the software system and the equipment are combined to achieve comprehensive detection of PCBA assembly.
WeLinkirt's AI vision technology provides an efficient and accurate solution for PCBA assembly inspection.
Quantifiable Results: By using WeLinkirt's solution, the detection effect of the manufacturer has been significantly improved. The detection rate has reached over 99%, the missed - detection rate has been reduced to less than 1%, and the false - alarm rate has been reduced by 80%. At the same time, the production - line model - changing time has been shortened from several hours to 5 minutes, greatly improving production efficiency and flexibility.