Application

Traditional manufacturing has long relied on manual labor to complete product assembly work, but with the growth of production demand, the efficiency and quality of manual operation can no longer meet the needs of efficient production. Especially in the case of high-precision requirements and large-scale production, manual operation is not only slow in assembly speed, but also has unstable quality, which greatly affects product quality and production efficiency.

Low production efficiency: Due to the manual operation method, the customer's production speed is slow and cannot meet the needs of large-scale production.

Product precision problem: Errors are prone to occur in manual production operations, resulting in unstable product quality.

Increase in production costs: In order to increase production, customers increase labor costs in production.

The company decided to introduce an intelligent production system that combines machine vision with automated robotic arms. The machine vision system accurately locates the product position, and then the robotic arm performs high-precision operations such as grabbing and assembly. This machine vision system can accurately and quickly complete product assembly tasks, improving production efficiency and quality.

Through the mutual cooperation between machine vision equipment: light sources, lenses, cameras, and industrial computer products, and through software configuration, production is made more portable.

By combining machine vision with a robot, the assembly accuracy reached the micron level, while reducing manual errors. The customer also increased production efficiency by 40% during production operations, achieving high-quality production. At the same time, it reduced manual involvement, reduced labor costs, and rework costs caused by manual errors, increasing corporate profits.

With the popularization of smart devices in manufacturing, the panel laminating industry is facing higher and higher production requirements. From laminating machines, binding machines to full laminating machines, these devices require high-precision alignment and laminating systems. Ordinary visual alignment systems can no longer meet the current production accuracy requirements. Therefore, after understanding the problem, the customer introduced machine vision equipment for high-precision alignment and laminating, which improved the company's product quality and production efficiency.

In the traditional bonding process, the precision requirements of the production process are getting higher and higher. With the speed of product updates and the intensification of market industry competition, ordinary machine alignment systems have shortcomings:

Machine accuracy problem: The machine is still using the early algorithm, and the accuracy can no longer meet the alignment requirements of current products.

Production efficiency bottleneck: Product accuracy does not meet user needs, rework or complaints occur, affecting production efficiency.

Production difficulty increases: In high-precision production requirements, small errors will lead to unqualified products, increasing the difficulty of quality control.

In order to solve the problems encountered by customers, ZhixiangShijue recommended a high-precision alignment and bonding system to them. This system is particularly suitable for FPC Bonding Sensor, Sensor and CG bonding, protective film/heat dissipation film and CG bonding, etc. It can provide up to ±5μm accuracy, ensuring that all components in the application can be accurately aligned and successfully bonded. The system uses advanced visual technology, which can accurately position and adjust the links in the production process in real time, improving the accuracy of the product and the stability of the production process.

The customer's machine can accurately guide every step of the FPC Bonding Sensor, Sensor and CG bonding during production, with an accuracy of ±5μm, greatly improving the bonding accuracy and reducing the product error rate. At the same time, the number of reworks during the production process was greatly reduced, saving delivery time and improving the company's overall production efficiency. The company's market competitiveness has also been significantly enhanced due to its product quality advantages during production.

In the precision manufacturing industry, a customer of Zhixiang Shijue needs to use 3D cameras for product inspection, especially for accurate measurement of the height and quality of precision pins in products. There is structural complexity in electronic products, so the installation position of the camera becomes difficult.

The position of the pin is hidden, which makes it extremely difficult to fully detect the position of the pin during product inspection. The pin is in the card slot, and it is difficult to see defects with the naked eye, so machine vision is needed for precise inspection. 3D cameras can take the state of the pin from multiple angles and accurately capture the position of the pin after production and whether the surface has defects.

Pin depth capture: The depth of the pin slot needs to be detected during the pin detection process, and traditional shooting methods cannot accurately measure it.

Pin shooting noise: The pin cannot be accurately aligned during shooting, resulting in noise in the captured image and inability to accurately detect.

Adjust the camera position: In order to solve the problem of noise in the shooting, it is recommended that customers use a 3D camera. The technician adjusts the camera and the product level during installation to ensure that the camera shoots at a horizontal angle, thereby reducing noise.

Optimize shooting method: The 3D camera has a 3D shooting effect. In view of the pin groove depth problem, the technical department designed to set the middle part of the pin as the bottom surface for machine adjustment to avoid the problem of pin groove wall blocking, and accurately measure the flat pin height.

Through careful adjustment and optimization of the 3D camera installation, the problems encountered during the shooting process were successfully overcome, and high-precision pin detection was achieved. It solved the inaccurate measurement encountered by customers in the test, improved the detection efficiency and product quality of the production line, and helped customers obtain better detection results in application scenarios with high precision requirements.