JP2009264876A - Inspection system of product quality, and its method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inspection system of product quality and its method. <P>SOLUTION: This inspection system of the product quality comprises an inspection tool, a photographing device, and an inspection module. This inspection tool is used for positioning a finished product as an inspecting object, the photographing device is erected on it, the correspondence relation between the positions of the both is kept not to change, and the inspection module performs the processing of a digital signal. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

The present invention relates to a product quality inspection system and method, in particular, by dividing an image into a plurality of pixel areas by an inspection module, and analyzing the pixel areas of a non-defective image and a product image to be inspected one by one as a comparison unit. The present invention relates to a product quality inspection system and method capable of achieving the purpose of fine analysis and collation.

A finished product of any product always includes a good product and a defective product.
In order to prevent users from purchasing defective products and affecting the trust of the company, all manufacturers sort defective products by quality control personnel before shipping the products.
Therefore, it can be said that quality control personnel play a considerably important role in the manufacturing process of products.

However, ordinary personnel usually tend to have the following defects in the product inspection process.
1. Quality control personnel may directly inspect the quality of the product with the naked eye. However, if fine wrinkles appear in the product, it is difficult to detect the wrinkles with the naked eye, and errors are likely to occur in the inspection results.
2. Quality control personnel sometimes inspect products with instruments, but also in the inspection process, there are elements of artificial operation, and quality control errors are likely to occur.
As described above, the above-described conventional inspection method has many drawbacks, and is not a good design, but has been expected to be improved.
In light of the shortcomings of each item derived from the above-described conventional inspection method, the present inventor tried to make new improvements as much as possible, and finally developed the product quality inspection system and method thereof after many years of hard work. Successful.

An object of the present invention is to provide a product quality inspection system and method.
The procedure is as follows. First, one or more non-defective images are stored in the inspection module, and the non-defective images are divided into a plurality of pixel areas, and an image of the inspection target product is taken by the photographing device. When the image is sent to the inspection module, the image of the inspection target product is similarly divided into pixel areas similar to the non-defective image, and the comparison comparison analysis is performed on the corresponding pixel area of the non-defective image and the inspection target product image. The quality of the inspection target product is accurately determined.
Another object of the present invention is to provide a product quality inspection system and method therefor, the procedure is to fix the product on the inspection equipment and to install the imaging device on the corresponding part of the product, All the dimensions of the images photographed by the photographing apparatus correspond to each other so that the comparison and analysis with the inspection module can be easily performed.

A product quality inspection system and method for achieving the object of the present invention includes an inspection tool, a photographing device, and an inspection module. The inspection tool is for fixing and standing a product. An imaging device is installed on the inspection equipment, the imaging device is associated with the product, the correspondence between the positions is always kept unchanged, and the imaging device and the inspection module are connected. In the inspection module, An inspection module that stores setting conditions for judging quality, first positions a non-defective product on the inspection device, takes one or more non-defective images by the photographing device, and sends the good product image to the inspection module. Converts a non-defective image into a digital signal, and further divides the non-defective image into a plurality of pixel areas so that the non-defective image serves as a reference for comparison with the inspection target product. When inspecting products, the inspection product is fixed on the inspection equipment, the image of the inspection object product is photographed by the photographing device, the image is transmitted to the inspection module, and converted into a digital signal. In the same way, the image of the product to be inspected is divided into a plurality of pixel areas in the same manner as the non-defective image, and the relative and absolute comparison analysis is performed for each corresponding pixel area of the non-defective image and the inspected product image. Thus, it is possible to accurately recognize the image difference between the inspection target product and the non-defective product, further acquire the content of defects of the inspection target product, and determine the quality of the inspection target product based on the quality setting condition.

The product inspection system and method according to the present invention have the following advantages over other conventional techniques.
1. The present invention stores in advance a standard value of each pixel area of one or a plurality of non-defective images in the inspection module, captures an image of the target finished product with an imaging device, and transmits the image to the inspection module. First, each pixel of the target product image is compared and compared with the average value of the digital signal of neighboring pixels, and the abnormal one is further compared and analyzed with the standard value of the pixel area corresponding to the non-defective image. Make an accurate decision.
2. The present invention secures the product on the inspection tool, installs an imaging device at the corresponding part of the product, and makes sure that the size of the images taken by the imaging device is the same size, and the inspection module compares and compares It is made easy to do.

With reference to FIG. 1, the product quality inspection system and method according to the present invention mainly includes an inspection tool 1, an imaging device 2, and an inspection module 3.
The inspection instrument 1 is for placing and positioning the product and standing the product on the inspection instrument 1.
The imaging device 2 is installed on the inspection instrument 1 and installed corresponding to the product fixed on the inspection instrument 1 so that the positional correspondence between the two does not change, and on the inspection instrument 1 This is because the adjusting device adjusts the shooting distance of the shooting device 2 so that the shooting device 2 can take a clear image. The photographing device 2 may be a camera or a photographing machine.
The inspection module 3 is connected to the imaging device 2 so that the image captured by the imaging device 2 can be received and stored, and the image is converted into a digital signal, and further processing is performed on the signal. In addition, the setting of the product inspection quality item and verification comparison analysis condition is stored in the inspection module 3.

FIG. 2 is a flowchart for acquiring a non-defective image by the product quality inspection system and method according to the present invention.
Here, an example of five non-defective images such as a red screen, a green screen, a blue screen, a gray screen, and a black screen on the LCD panel will be described as an example, and a procedure for acquiring the non-defective images will be described.

Step 1: First, a good LCD panel (non-defective product) is fixed on the inspection tool 101.
Step 2: Shoot five non-defective images such as a red screen, a green screen, a blue screen, a gray screen, and a black screen on the LCD panel by the photographing device 2, and transmit the five non-defective images to the inspection module 102.
Step 3: When the inspection module receives the non-defective images of the five LCD panels, the non-defective images are first converted into digital signals, and each non-defective image is further divided into a plurality of pixel areas 103.
Step 4: The standard value including the maximum value / minimum value and the average value of each pixel area is calculated, and the standard value for each pixel area of each non-defective product image is used as a reference 104 for judging whether the product is good or bad. If the image is taken with 3 million pixels, the good image may be divided into pixel areas in units of 100 * 100 pixels, and the good image may be further divided into 300 pixel areas. The 3 million pixel and 100 * 100 pixel areas may be set as needed and do not limit the scope of the claims of this application.
Step 5: Save the standard value 105 generated in the non-defective image.

FIG. 3 is a flowchart of an inspection module setting procedure of the product quality inspection system and method according to the present invention. The LCD panel is taken as an example in order to make the explanation easy to understand, and the procedure is as follows. .

Step 1: The inspection item 201 of the LCD panel as a product is input through the input interface, for example, bright dots, dark dots and scratches on the LCD panel.
Step 2: The determination condition of the non-defective product and the defective product, for example, the standard such as the number of dark dots and bright dots and the length of the scratches is input through the input interface. Non-defective products may be further subdivided, and products that have been inspected may be divided into each grade.
Step 3: The inspection item can be increased or decreased 203 through the input interface.
Step 4: Quality judgment conditions and non-defective grades can be modified 204 through the input interface.
Step 5: Save the set data 205.

FIG. 4 is a flowchart of the inspection step of the LCD panel according to the present invention.
The procedure is
Step 1: Fix the inspection target LCD panel (target product) on the inspection tool 301.
Step 2: Capture five target product images using the imaging device as the red LCD screen, blue screen, green screen, gray screen and black screen, respectively, and the five target product images to the inspection module. 302 transmission.
Step 3: The inspection module converts the five target product images into digital signal data 303.
Step 4: First, a relative comparison and collation is performed on the average value of the digital signal of each pixel area of the target product image and the digital signal of neighboring pixels, and abnormal pixels 304 are selected. If any pixel is normal, the test result is output 308 as a report.
Step 5: The abnormal pixel of the digital signal is further subjected to absolute comparison with the standard value of the pixel area of the corresponding good image, and the comparison result is analyzed to determine the wrinkle attribute 305 of the pixel.
Step 6: Organize the areas of the area in units of pixel areas, and determine the area type 306 of the area.
Step 7: Quality grades are judged one by one based on quality standards, and product grade classification 307 is performed. Finally, the inspection result is output as a report 308.

The black screen of the non-defective image photographed in the above step 2 is used for the comparison comparison inspection of the scratch of the target product. In the photographing process, the illumination light is projected onto the target product, and if there is a scratch, the inspection is performed. Reflected light appears in the target product image transmitted to the module, and this is collated and compared for each pixel area of the non-defective image, and the situation of the scratch is detected by finding a difference portion.

In addition, the non-defective product image and the target product image are divided into a plurality of pixel areas, and the length and width sizes of each pixel area are the same and are specified as such. By comparing and comparing the pixel areas, for example, the length and area of each item such as the length of the scratches and the area of the stain can be calculated.

Furthermore, the above LCD panel inspection is a more preferred mode of implementation of the present invention and does not limit the scope of the present invention. The present invention is not limited to other products such as conductors / circuit boards or other Therefore, in the present invention, one or a plurality of non-defective images may be taken and stored in the inspection module according to the type of the product to be inspected.

The foregoing detailed description is a specific description of possible embodiments of the invention, which are not intended to limit the patent scope of the invention and are made without departing from the spirit of the invention. All equivalent implementations or modifications are intended to be within the scope of the claims.

1 is a system diagram of a product quality inspection system and method according to the present invention. It is a flowchart which acquires a non-defective image in the product quality inspection system and method according to the present invention. 5 is a flowchart for setting an inspection module in the product quality inspection system and method according to the present invention. It is a product quality inspection system according to the present invention and a target product inspection flowchart in the method.

Explanation of symbols

1 Inspection equipment 2 Imaging device 3 Inspection module

Claims (10)

A product quality inspection system,
Inspection equipment 1 for placing and positioning the product and placing it upright,
An imaging device 2 installed on the inspection instrument 1 and installed corresponding to the product on the inspection instrument 1;
An inspection module 3 connected to the imaging device 2 and capable of receiving and storing an image signal captured by the imaging device 2 and converting the image signal into a digital signal;
The inspection items of the product stored in the module in advance and the corresponding non-defective product standard and defective product standard can be corrected by an external interface according to the customer's demand and can be used as a quality judgment standard. A plurality of non-defective images are divided into a plurality of pixel areas for each image, and standard values of the pixel areas are calculated.
The inspection target product is fixed on the inspection instrument 1 and the image of the inspection target product is photographed by the photographing device 2 and the inspection target product image is transmitted to the inspection module 3. Is converted into a digital signal for each image, and an abnormal pixel is detected by first comparing the pixel signal of each image with the average value of the surrounding pixel signals, and further detecting the abnormal pixel in the pixel area. Compare and analyze the standard value of the non-defective image and determine whether the product to be inspected is non-defective or defective based on the setting conditions of the non-defective product.
A product quality inspection system. The product quality inspection system according to claim 1, wherein an adjustment device is provided on the inspection tool 1 so that a focal length of the photographing device 2 can be adjusted. The product quality inspection system according to claim 1, wherein the product inspection items stored in the inspection module 3 can be arbitrarily increased or decreased. The product quality inspection system according to claim 1, wherein the non-defective product comparison / comparison conditions stored in the inspection module can be arbitrarily changed. 2. The product quality inspection system according to claim 1, wherein a product classification setting is stored in the inspection module to further classify a product to be inspected. 3. When the inspection module 3 receives a non-defective image and a product image to be inspected, it first classifies each pixel area, and a standard value for each pixel area of the non-defective image is detected before inspecting the inspection target product. The product quality inspection system according to claim 1, wherein: A product quality inspection method comprising the following steps:
First, a non-defective product is fixed on the inspection instrument 1, and one or a plurality of non-defective images are photographed by the imaging device 2 on the inspection instrument 1 and sent to the inspection module 3. The inspection module 3 sends a non-defective image signal. After the conversion to the digital signal, the non-defective image is further divided into a plurality of pixel areas, and the standard value for each pixel area of the non-defective image is calculated. Save the settings, step 1,
Fixing the product to be inspected on the inspection device 1, and taking an image of one or a plurality of products to be inspected by the photographing device 2 and transmitting the image to the inspection module 3;
Step 3 in which the inspection module 3 converts the image of the product to be inspected into a digital signal;
Collating and comparing the digital signal of each pixel of the product to be inspected with the average value of the surrounding pixel signals, and selecting abnormal pixels;
Comparing the abnormal pixel of the digital signal with the standard value of the pixel area of the non-defective image and analyzing the result of the comparison to determine the type of wrinkles;
Step 6 determines the type by comprehensively organizing the tiles in each zone in units of pixel zones,
Step 7 to perform quality judgment based on the set quality condition, and if the defect is slight, classify the product and output the inspection result as a report;
A method for inspecting product quality, comprising: 8. The product quality inspection method according to claim 7, wherein when the inspection module determines in step 7 that the product to be inspected is a non-defective product or a defective product, all inspection results are output as a report. The non-defective image and the product image to be inspected are divided into a plurality of pixel areas, the length and width of each pixel area are the same size, and the known length and area are specified. The product quality inspection method according to claim 7, wherein the length and area of each item can be calculated by a model for comparison. 8. The product quality inspection method according to claim 7, wherein in step 4, if all the pixels are all normal, the inspection result is output as a report.

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