Intelligent Visual Inspection Technology
20151001 - 20170630
Dr Chen-jung Tsai
1. Develop mixed characteristic surface visual inspection technologies, including (1) Develop human eye bionic illumination optical system: a) light distribution angle: ≤20 degree ; b) Brightness: >500 LUX (2) Develop image enhancement algorithm for projection image and capture image compensation (3) Develop large size 3D measurement methodology including pattern generation system and point cloud generation algorithm: a) FOV: >150mm, b) detected size 0.1~1mm (diameter) (4) Develop machine learning based illumination optimization & defect detection methodology (5) Develop anti-glare image capture optical design with locally tunable dynamic range: a) Micro-display panel resolution: <1024x720; b) Image sensor resolution: >2.0M pixels, c) F-number: >3.0 (6) Develop mixed characteristic surface visual inspection system: • Object size: <350x350mm • Defect size: >0.15mm • Operation speed: <10s/station 2. Develop multiple layers transparent surface visual inspection technologies, including: (1) Develop all in focus image capture system, including: optical/mechanical/electrical designs: a) Sensor resolution: ≥1.0M pixels; b) FOV: <20x20mm; c) Optical depth: <50um; d) F-number: >3.0; e) Working distance: >5mm (2) Develop blur image comparison methodology for defect detection. (3) Develop multiple layer transparent surface visual inspection system: • Detected thickness: 50um~800um • Object size: 3~8” • Depth of focus(DOF): <50um • Defect size: >0.1mm (point) • Operation speed: <5 second/single surface 3. Develop curve transparent surface visual inspection technologies, including: (1) Develop curve transparent surface image capture technology, including: optical/mechanical/electrical designs: a) Resolution of spatial light modulator: < 1024x720 b) Sensor resolution: ≥2.0M pixels; c) FOV: >6x6mm; d) Optical depth: >0.5mm; e) F-number: >3.0; f) Working distance: >10mm (2) Develop curve transparent surface visual inspection system: • Object size: 2~20mm (in diameter) • Depth of focus(DOF): >0.5mm • Defect size: >0.01mm • Operation speed: <5s/object 4. Contract service deliverables for Customer (1), including: (1) One set of prototype for touch panel (OGS (One Glass Solution, 一體化觸控) without projection film) defects inspection: • Measurement area: front/back panel • Object size: 3~8” OGS panel • Defect size: >0.1mm (point) • False detected rate: <1% • Fail detected rate: <0.1‰ • Operation speed: <5 second/single surface (2) One set of prototype for touch panel (OGS (One Glass Solution, 一體化觸控) with projection film) defects inspection: • Measurement area: front/back panel • Object size: 3~8” OGS panel • Depth of focus(DOF): <50um • Defect size: >0.1mm (point) • False detected rate: <2% • Fail detected rate: <0.5‰ • Operation speed: <5 second/single surface 5. Industrial implementation of the project deliverables: Industrial trial run of project deliverables in Customer (1)'s factory or other industrial partner’s production line.
Mr Pei Chin, Ryan Chung Mr Kin Lung, Kenny Chan Ms Ying, Anna Liu Dr Xiu Ling Zhu Mr Derek Dehu Liu Mr Wei-ping Tang Mr Chang-li Wu Dr Chi Yong Mr Chun Yip Wong Dr Xueyan Tang Ms Wei, Wendy Zhang Mr Jie KOU Dr Zhao, Fiona Wang Mr Chuanyun Deng Mr Chi Kin Wong Dr Yan Wang Mr Yuk lung, Alex Cheung Mr Chak Wai Chau Mr Kwok Chung Chan Mr Hon Lung Cheung Ms jie, Fion Lu Ms Siqi, Cathy Li Mr Weiwen, Wilman Zou Ms Hui, Tracy Hu Ms Ka Man Liu Mr Wai Kin Luk
K&K CORPORATION LTD K&K Corporation Ltd. (Licensing) [Sponsor] Kopin (HK) Limited [Sponsor] Truly Opto-Electronics Limited [Sponsor] Truly Opto-Electronics Limited (Contract Service) [Sponsor] Truly Opto-Electronics Limited (Licensing) [Sponsor]
The surface quality is an essential determining factor for both the end product appearance and the component function in manufacturing field. Taking an iPhone OEM factory as an example, more than 30% manpower was consumed on the appearance inspection during the manufacturing process. The inspection manpower cost is up to 4.8 Billion RMB per year. However, with over 10% annualized rate of average wage growth in China, the low-cost labor force will no longer exist. Reducing manpower cost has become the most important and urgent problem to be solved for the manufacturers. To replace the expensive labor force, automatic visual inspection systems employing intelligent image capturing and image processing technologies were highly demanded. The systems can offer efficient solutions to increase both production speed and quality. The R&D focus of this project is to develop a system level intelligent in-line surface defect visual inspection technology platform for variable characteristics surfaces. The project team will focus on developing the following IP protected platform technologies, including: 1) Multiple layers transparent surface defects inspection technology, 2) Curved transparent surfaces defects inspection technology, and 3) Mixed characteristics surface defects inspection technology. The above technologies can be widely applied to the inspection of the consumer electronics, of which over 60% worldwide shipments were made in China. It was forecasted by IDC that in 2014, the worldwide shipments of smart phone can be up to 1.2 billion units, tablets will be 260.9Milion units and PC (Notebook + Desktop) will be 295.9Milion units. Particularly the increasing trend will be kept in the coming few years. Therefore, it means that the demanding shipments of such visual inspection equipment will be more than 20000 units per year. Supposing the unit price was 1million RMB, the overall generated industrial production value by the technology platform will exceed 20 billion RMB annually.