Abstract
Automatic optical inspection (AOI) is a control process for precisely evaluating the completeness and quality of manufactured products with the help of visual information. Automatic optical inspection systems include cameras, light sources, and objects; AOI requires expert operators and time-consuming setup processes. In this study, a novel autonomous industrial robot-guided inspection system was hypothesized and developed to expedite and ease inspection process development. The developed platform is an intuitive and interactive system that does not require a physical object to test or an industrial robot; this allows nonexpert operators to perform object inspection planning by only using scanned data. The proposed system comprises an offline programming (OLP) platform and three-dimensional/two-dimensional (3D/2D) vision module. A robot program generated from the OLP platform is mapped to an industrial manipulator to scan a 3D point-cloud model of an object by using a laser triangulation sensor. After a reconstructed 3D model is aligned with a computer-aided design model on a common coordinate system, the OLP platform allows users to efficiently fine-tune the required inspection positions on the basis of the rendered images. The arranged inspection positions can be directed to an industrial manipulator on a production line to capture real images by using the corresponding 2D camera/lens setup for AOI tasks. This innovative system can be implemented in smart factories, which are easily manageable from multiple locations. Workers can save scanned data when new inspection positions are included based on cloud data. The present system provides a new direction to cloud-based manufacturing industries and maximizes the flexibility and efficiency of the AOI setup process to increase productivity.
Highlights
In modern industries, robots are increasingly required to perform complex tasks
The present system provides a new direction to cloud-based manufacturing industries and maximizes the flexibility and efficiency of the automatic optical inspection (AOI) setup process to increase productivity
Robotics has been crucial in loading/unloading, assembly, testing, and inspection processes
Summary
Robots are increasingly required to perform complex tasks. Robot integration involves automating the relevant processes to ensure satisfactory quality. Automatic optical inspection engineers can strategize AOI positions and the corresponding robot trajectory regardless of time and location without the presence of the physical product, industrial manipulator, inspection camera, or lens by only using scanned data. The robot position can be conveniently determined using a virtual robot and product in OPEN CASCADE (OCC) software This method reduces the complexity of system development for managing the movement of a robot carrying a camera and lens. This system can be managed from multiple locations and allows users to define new optical inspection positions from cloud data based on scanned information without the presence of the physical object. Whereas, exiting AOI systems still requires physical set-up to perform inspections, which makes it more challenging to manage from multi-locations
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