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Customer requirements: product inspection cycle:

per second Affixing any point after deformation, a high degree of deviation of less than 0.1mm

Full 3D scan

Z-scan accuracy is 0.02mm

Technical program:

1) a full 3D scan, full 3D data to compare with the standard value, if less than 0.1mm, by otherwise NG

2) a high degree of Z accuracy of 0.02mm

3) due to the requirements of precision and speed, the system needs the United States Stockeryale 40mW precision cohesive energy of the laser line generator made in Germany Ranger 3D high-speed scanning CCD, the center of industrial grade lens, servo drive system. This is currently the only configuration that can meet the requirements.

4) scanning laser line with 40mm width, a product scan once a second.

5) The last machine system is probably the same as in the following picture.

Consider the following use of existing equipment scan results.

1) due to the lens and the laser is not this project uses, so the need to scan 2 times to get all the 3D data of a workpiece.

2) the lowest bit with the highest bit of the scanning surface of the workpiece is probably a difference of 13mm (not the thickness of the workpiece), the gradient level 640, 0.02mm, 0.1mm deformation of the requirements should be met.


Technical Proposal:

1) Full 3D scan, get all point 3D data, and compare with standard. If less than 0.1mm, it will pass.

2) Z 3D data accuracy are 0.02mm.

3) Because of the accuracy and speed requirement, the system should be configured with American made Stockeryale 40mW accurate laser line generator, German made Sick Ranger 3D scan CCD, industrial tele lense, servo system. Per to our assessment, it is the only configuration to achieve the requirements.

4) With 40mm width scan laser and telescope lens, it will take about 1 sec to scan 1 pcs.

5) The final machine configuration will be similar to the following picture machine.

Please see the following scan result with the current available machine.

1) Because the lens and laser model are NOT for this scan purpose, it will need 2 scans for each pcs.

2) The depth between top of the cover and bottom (for the scan surface) is about 13mm. The current accuracy is 640 pixels. That is said the accuracy is 0.02mm. It should satisfy Xinhao's 0.1mm warpage check requirement.

20121210105751095109.jpg

1) above and the left has a prominent rectangular, is a prominent part of the temporary fixture block cover some part, not the normal 3D data show

2) display Pass and Fail font is provide some sample tag

3) Because the accuracy of the test for a 0.02mm, limit is 0.1mm, and passing the sample difference is less than four 0.08mm for passing, four or more for not passing. Red zone for failing part, that the difference

4 4) in accordance with the diagram representation of the subregion access point comparison, the results are as follows:

1) There are shadows on top and left. This is the edge of the temporary cover fixture to block part of the cover. These are not the normal 3D data.

2) The "Pass" and "Fail" on the image are the mark on the sample cover.

3) The accuracy for the test is 1 grade 0.02mm and the limit is 0.1mm. That is said if there is more than 4 grades 0.08mm in any point height on the cover (compare to the "Pass" cover), it will be fail and marked in red. The red area are Fail in the image.

4) Take some points for compare from the images. The results are as below:

2012121010570582582.jpg


20121210105788588858.jpg
20121210105727392739.jpg
Following in the rear cover placed a small piece of tissue paper, paper having a thickness of 0.09-0.1mm (that is the required height change values), the scanning can be apparent to the difference of the contour, the data is about 10 (about 0.2mm, Because there may be some gaps).
20121210105842944294.jpg2012121010580920920.jpg20121210105894059405.jpg

Your concerns:

1) How to use the 3D data to check the scan cover warpage?

We have all 3D data for whole surface. Take a point in the cover and gets its Z as Z1. Compare with the same point in the standard cover Z data as ZS. If Z1 and ZS difference is higher than 0.1mm, the cover fails . We can program to compare as many points as requests.

2) How to get the same point in different pcs?

We will use machine vision method to extract the cover profile for the scan surface. Then we set 1 base 0 point, for example the 1st left point on profile of every scan. We need to check the point X1, Y1, Z1 (the point is located on X1, Y1, Z1 according to 0 point). Then we can find every scan surface's 0 point and its X1, Y1, Z1 point and then compare all the X1, Y1, Z1 with the standard X1, Y1, and Z1 .

3) How to set a standard surface to be compared?

Just put a standard cover to be scan and get all its 3D data. All these data can be compared with other covers.

4) How to generate a standard cover?

Every actual cover is not 100% perfect with lower than limit defects. It is not the meaning standard cover. The standard cover is generated by a mathematics model to scan many "pass" covers. The model will analysis all same point data and gets a standard point data.

Customer concern:

1) how to use 3D data check workpiece deformation degree?

We have been able to get the full face 3D data. Taken on the lid a little, and its height is Z1. The same point on the lid with the standard height value ZS do the comparison, if the difference is greater than 0.1mm, for failing. Compare as many points of the various parts can be programmed as required.

2) how to get the same point in different workpiece?

Using machine vision software to extract the contours of the rear cover. You can find a suitable point to zero. For example, take the lid to the upper left of the first point to zero. We want to check the point relative to the zero of X1, Y1, and Z1. Then we can take on a different cover the same zero to draw different backcover same point X1, Y1, and Z1, and then based on the coordinate.

3) How to set up a standard for comparison surfaces?

The cover, into a standard scan to acquire the entire 3D data. The data to be seized of the back cover.

4) How to produce a standard surface?

An actual back cover is not 100% perfect. Scan of the so-called standard rear cover only error is less than the requirements. Standard rear cover is generated by a mathematical model, the software to scan a lot of the back cover is considered a pass to come to the surface of a standard mathematical analysis methods the standard curved surfaces is available for comparison.

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