Adjustable panoramic inspection system for submillimeter fasteners

Yung-Jhe Yan; Ming-Shiou Tsai; Wen-Bin Chen; You-Bo Chen; Ching-Cherng Sun; Mang Ou-Yang

doi:10.1364/AO.386555

Applied Optics
Vol. 59,
Issue 11,
pp. 3467-3475
(2020)
•https://doi.org/10.1364/AO.386555

Adjustable panoramic inspection system for submillimeter fasteners

Yung-Jhe Yan, Ming-Shiou Tsai, Wen-Bin Chen, You-Bo Chen, Ching-Cherng Sun, and Mang Ou-Yang

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Yung-Jhe Yan, Ming-Shiou Tsai, Wen-Bin Chen, You-Bo Chen, Ching-Cherng Sun, and Mang Ou-Yang, "Adjustable panoramic inspection system for submillimeter fasteners," Appl. Opt. 59, 3467-3475 (2020)

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Abstract

Fasteners are critical and indispensable locking components in mechanical assembly. Submillimeter fasteners are massively and widely used in electronic devices. This study proposed an adjustable panoramic inspection system for M2 to M0.8 submillimeter fasteners. The system mainly consists of a panoramic imaging module, a back-light module, and an image grabbing and computing module. The panoramic imaging module would form four equal optical path lengths to keep the same imaging amplification between the different directions of the field of view. The back-light module was designed to provide uniform illumination and enhance the contrast of the pitch edge between the fasteners and the background. The image grabbing and computing module with a high-speed camera was designed to be adjustable for different sizes of submillimeter fasteners. The realized system can offer the function of four images in one shot to make a panoramic scene, independent illumination for recognizing, inspect screws from M0.8 to M2.0 screws, and short time consumption of image processing, such as 3.284 ms for M0.8 screws and 2.384 ms for M2.0 screws, to achieve examination of 6000 pieces in 1 min.

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	Name
Feature	Bartelt et al. [25]	St. Onge et al. [26]	Spalding [27]	Nygaard [23]	NCTU
Light source type	LEDs	LEDs & lasers	Lasers	LEDs	LEDs
Light source amount	1	3	4	1	5
Light sources with independent control	X	O	O	X	O
Illumination type	A ring light for forward lighting	A ring light for forward lighting	N/A	A light for forward and reflective backward lighting	A ring light for forward lighting and four independent LEDs plate for backward lighting
Inspecting sensors	$> 8$ Cameras	$> 8$ Cameras & 4 Detectors	$> 4$ Detectors	Single camera	Single camera
Expected detection speed	N/A	N/A	N/A	N/A	6000 pcs/min
Panoramic images	Different frames at different cameras	Different frames at different cameras and detectors	Different frames at different detectors	Four panoramic images in one shoot of a camera	Four panoramic images in one shoot of a camera
Image contrast	Normal	Normal	Normal	Good	Best
Inspection object and its size	Larger than M10 of cartridges	Larger than M10 of cartridges	Larger than M50 of fasteners	Larger than M10 of fasteners or cartridges	M2–M0.8 of screws
Mechanism volume	Large	Large	Normal	Small	Small

	M0.8 Screw	M2.0 Screw
pitch	0.2 mm	0.4 mm
$D$	1.6 mm	3.0 mm
$D^{'}$	2.67 mm	5.0 mm
$D^{''}$	0.8 mm	2.0 mm
Required spatial resolution (10 pixel/pitch)	20 µm/pixel	40 µm/pixel
$W$	10.67 mm	20.0 mm
$L$	0.95–3 mm	0.95–3 mm
Target CCD resolution	$P_{W}$	534 pixels	500 pixels
Target CCD resolution	$P_{L}$	150 pixels	150 pixels

Forward optical path	Name	Coordinate
	Object	(0, 0)
	Mirror 3	$(- (L_{2} + X), - (L_{2} + X))$
	Mirror 4	$(L_{2} + X, - (L_{2} + X))$
	Mirror 5	$(a, - (L_{1} + X))$ ; $(- a, - (L_{1} + X))$
	Mirror 6	$(- (L_{2} + X), - (L_{1} + X))$
	Mirror 7	$(L_{2} + X, - (L_{1} + X))$
	Optical path length	$(\sqrt{2} + 2) (L_{2} + X) - L_{1} - X - a$
Backward optical path	Mirror 1	$(- (L_{3} + X), L_{3} + X)$
	Mirror 2	$(L_{3} + X, L_{3} + X)$
	Mirror 8	$(b, L_{3} + X)$ ; $(- b, L_{3} + X)$
	Optical path length	$(\sqrt{2} + 2) (L_{3} + X) + L_{1} + X - b$

Name	Mako G-032C	Max. Frame Rate	102 fps
Resolution	$658 \times 492$	Pixel size	7.4 µm
Sensor size	${1 / 3}^{''}$ , $4.869 \times 3.641 m m$	Bit depth	8/12 bit
Auto exposure	10 µs–93 s	Trigger delay	$< 1 µ s$

Name	MLH-10X
Max. magnification	0.084 mm–0.84 mm	Back Focal length	23.29 mm
Operation range	F5.6–F32C	Working distance	150–450 mm
Field of view ( $W D = 150 m m$ )	71.4–7.1 mm (D); 57.1–5.7 mm (H); 42.9–4.3 mm (V)
Angle of view	17.0°–3.3°(D); 13.8°–2.7°(H); 10.6°–2.0°(V)

Name		Coordinate	Width and Limitation	M0.8 (mm)	M2.0 (mm)
Forward optical path	Object	$(0, 0)$	$= D^{'}$	2.67	5.0
	Mirror 3	$(- (L_{2} + X), - (L_{2} + X))$	$\geq D^{'} / \sin ({67.5}^{\circ})$	2.89	5.41
	Mirror 4	$(L_{2} + X, - (L_{2} + X))$	$\geq D^{'} / \sin ({67.5}^{\circ})$	2.89	5.41
	Mirror 5	$(a, - (L_{1} + X))$ ; $(- a, - (L_{1} + X))$	$\geq \sqrt{2} D^{'}$	3.78	7.07
	Mirror 6	$(- (L_{2} + X), - (L_{1} + X))$	$\geq \sqrt{2} D^{'}$	3.78	7.07
	Mirror 7	$(L_{2} + X, - (L_{1} + X))$	$\geq \sqrt{2} D^{'}$	3.78	7.07
	$L_{1}$	none	$\geq (D^{'} + \sqrt{2} T) / 2$	4.87	6.04
	Optical path length	$(\sqrt{2} + 2) (L_{2} + X) - L_{1} - X - a$	none	107.25	116.86
Backward optical path	Mirror 1	$(- (L_{3} + X), L_{3} + X)$	$\geq D^{'} / \sin ({67.5}^{\circ})$	2.89	5.41
	Mirror 2	$(L_{3} + X, L_{3} + X)$	$\geq D^{'} / \sin ({67.5}^{\circ})$	2.89	5.41
	Mirror 8	$(b, L_{3} + X)$ ; $(- b, L_{3} + X)$	$\geq 2 \sqrt{2} D^{'}$	7.55	14.14
	$L_{3}$	none	$\geq 3 D^{'} / 2$	4.01	7.5
	Optical path length	$(\sqrt{2} + 2) (L_{3} + X) + L_{1} + X - b$	none	107.25	116.86
$L_{2}$		none	$\geq \frac{(\sqrt{2} + 2) L_{3} + 2 X + 2 L_{1} - D^{'}}{\sqrt{2} + 2}$	18.38	21.88

	M0.8 Screw ( $D = 1.6 m m$ ; $F = 0.6$ )	M2.0 Screw ( $D = 3.0 m m$ ; $F = 0.6$ )
Distance between two screws	$\frac{32 \sqrt{2}}{15} ≅ 3.0 m m$	$4 \sqrt{2} ≅ 5.7 m m$
The time duration between two screws in 6000 pc/s	10 ms	10 ms
Velocity between two screws	0.3 m/s	0.57 m/s
Single-pixel size of CCD	7.4 µm	7.4 µm
The exposure time on a single-pixel CCD	24.7 µs	13.0 µs
Time on trigger range	5.33 ms	5.26 ms
Frequency of the image trigger on screw detection	$\geq 187.5 H z$	$\geq 190.0 H z$

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Tables (7)

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Applied Optics