Claims
- 1. A method for inspecting a composite tape including a cover tape bonded to a carrier tape along first and second seal tracks, the method comprising the steps of:
capturing a digital image of the composite tape; inspecting the digital image for defects; and if a defect is found, generating a fault condition.
- 2. The method of claim 1, wherein said inspecting step includes the steps of:
capturing a portion of the digital image including the first seal track; dividing the portion of the digital image into a plurality of segments; inspecting each segment of the seal track digital image; and assigning a passing or failing grade to each segment.
- 3. The method of claim 2, wherein said inspecting each segment step includes the step of determining whether the seal is continuous within the segment; and wherein said assigning step includes assigning a failing grade to the segment if the seal is not continuous within the segment.
- 4. The method of claim 2, wherein said inspecting each segment step includes the step of measuring the width of the seal track within the segment; and wherein said assigning step includes the steps of comparing the width to a minimum width and assigning a failing grade to the segment if the width is below the minimum width.
- 5. The method of claim 2, wherein said inspecting each segment step includes the steps of determining whether the seal is continuous within the segment and measuring a width of the seal within the segment; and wherein said assigning step includes the step of assigning a failing grade to the segment if the seal is not continuous within the segment or if the width is below the minimum width.
- 6. The method of claim 2, wherein said inspecting step includes the steps of:
determining a number of consecutively-failed segments for the portion of the digital image; and comparing the number of consecutively-failed segments to a defect tolerance.
- 7. The method of claim 1, wherein said step includes the steps of:
finding an edge of the carrier tape within the digital image; and predicting an area of the digital image where one of the seal tracks is likely to be based on the position of the carrier tape edge.
- 8. The method of claim 7, wherein said finding step includes using a gradient-based edge tool to find the carrier tape edge within the digital image.
- 9. The method of claim 7, wherein said inspecting step further includes using a gradient-based edge tool to find seal track edges within the predicted area where one of the seals track is likely to be.
- 10. The method of claim 1, wherein said inspecting step includes the steps of:
determining robust line equations for the first and second seal tracks; calculating the distance between the first and second seal tracks based on the equations; comparing the distance between the seal tracks with an acceptable value; and assessing whether there is a defect in the seal tracks spacing.
- 11. The method of claim 1, wherein said inspecting step includes the steps of:
determining a robust equation for an edge of the carrier tape; determining a robust equation for an edge of the cover tape; using the equations to determine the distance between the edges; comparing the distance between the edges with an acceptable value; and assessing whether there is a defect in the spacing between the edges.
- 12. The method of claim 1, wherein said inspecting step includes the steps of:
determining a robust equation for an edge of the carrier tape; determining a robust equation for the first seal track; using the equations to determine the distance between the carrier tape edge and the first seal track; comparing the distance between the carrier tape edge and first seal track with an acceptable value; and determining whether there is a defect in the spacing.
- 13. The method of claim 1, wherein said inspecting step includes the steps of:
positioning first, second, third, and fourth boxes in the digital image in the nominal positions of a carrier tape edge, a cover tape edge, the first seal track, and the second seal track, respectively; performing a gradient-based edge tool function on the data within the first, second, third, and fourth boxes to formulate a robust line equation for each of the carrier tape edge, cover tape edge, first seal track, and second seal track; using the robust line equations to calculate the spacing between the edges of the carrier tape and cover tape; using the robust line equations to calculate the spacing between the cover tape edge and the seal track; using the robust line equations to calculate the spacing between the first and second seal tracks; and comparing the calculated spacings to nominal values; and assessing whether there are irregularities in the cover tape and seal track positioning.
- 14. The method of claim 1, wherein said generating step includes the step of notifying an operator of the defect.
- 15. A packaging and inspection machine for packaging parts in a composite tape and inspecting the composite tape for defects, the composite tape including a cover tape bonded to a carrier tape along first and second seal tracks, the machine comprising:
a camera configured to acquire an image of the composite tape; and a controller in communication with the camera to receive the acquired image, the controller being configured to
analyze the acquired image for defects in the composite tape, and generate a fault condition if a defect is detected.
- 16. The machine of claim 15, further comprising:
a transport configured to deposit parts in compartments of the carrier tape; a cover tape application and sealing module configured to seal the cover tape to the carrier tape along the first and second seal tracks, thereby capturing the parts within the carrier tape compartments and resulting in the composite tape.
- 17. The machine of claim 16, wherein the transport is a pick-and-place transport.
- 18. The machine of claim 15, further comprising an output device in communication with the controller, the output device being configured to generate an output in response to the generation of the fault condition, the output informing an operator of the detected defect.
- 19. The machine of claim 15, wherein the controller is configured to analyze the acquired image by being further configured to inspect the seal tracks for faults.
- 20. The machine of claim 19, wherein the controller is configured to inspect the seal tracks by being further configured to
capture a portion of the digital image including the first seal track; divide the portion of the digital image into a plurality of segments; inspecting each segment of the seal track digital image; and assigning a passing or failing grade to each segment.
- 21. The machine of claim 20, wherein the controller is configured to inspect each segment by being further configured to determine whether the seal is continuous within the segment; and wherein the controller is configured to assign a passing or failing grade by being further configured to assign a failing grade to the segment if the seal is not continuous within the segment.
- 22. The method of claim 20, wherein the controller is configured to inspect each segment by being further configured to measure a width of the seal track within the segment; and wherein the controller is configured to assign a passing or failing grade by being further configured to compare the width to a minimum width and assign a failing grade to the segment if the width is below the minimum width.
- 23. The machine of claim 15, wherein the seal tracks have a spacing, and wherein the controller is configured to analyze the acquired image by being further configured to analyze whether there is a defect in the spacing of the seal tracks.
- 24. The machine of claim 23, wherein the control is configured to analyze whether there is a defect in the spacing of the seal tracks by being further configured to:
determine robust line equations for the first and second seal tracks; calculate the distance between the first and second seal tracks based on the equations; compare the distance between the seal tracks with an acceptable value; and assessing whether there is a defect in the seal tracks spacing.
- 25. The machine of claim 15, wherein the cover and carrier tapes have an edge, respectively; and wherein the controller is configured to analyze the acquired image by being further configured to analyze whether there is a defect in a spacing between the edges.
- 26. The machine of claim 25, wherein the control is configured to analyze whether there is a defect in a spacing between the edges by being further configured to
determine a robust equation for the carrier tape edge; determine a robust equation for the cover tape edge; use the equations to determine the distance between the carrier tape and cover tape edges; compare the distance between the edges with an acceptable value; and assess whether there is a defect in the spacing between the edges.
- 27. The machine of claim 15, wherein the carrier tape has a tape edge; and wherein the controller is configured to analyze the acquired image by being further configured to analyze whether there is a defect in a spacing between the carrier tape edge and the first seal track.
- 28. The machine of claim 27, wherein the control is configured to analyze whether there is a defect in a spacing between the carrier tape edge and the first seal track by being further copyrighted to
determine a robust equation for the carrier tape edge; determine a robust equation for the first seal track; use the equations to determine the distance between the carrier tape edge and the first seal track; compare the distance between the carrier tape edge and first seal track with an acceptable value; and assess whether there is a defect in the spacing.
- 29. The machine of claim 15, wherein the controller includes a processor and a memory, the memory including one or more software modules executable by the processor to configure the controller.
- 30. The machine of claim 29, wherein the software modules include a carrier tape edge (CTE) tool that defines a robust equation for an edge of the carrier tape.
- 31. The machine of claim 30, wherein the CTE tool includes a gradient-based edge tool to locate transitions corresponding to the edge of the carrier tape.
- 32. The machine of claim 29, wherein the software modules include a cover tape location (CTL) tool that defines a robust equation for an edge of the cover tape.
- 33. The machine of claim 32, wherein the CTL tool includes a gradient-based edge tool to locate transitions corresponding to the edge of the cover tape.
- 34. The machine of claim 29, wherein the software modules include a seal track location (STL) tool that defines first and second robust equations for the first and second seal tracks, respectively.
- 35. The machine of claim 34, wherein the STL tool includes a gradient-based edge tool to locate transitions corresponding to the edges of the seal tracks.
- 36. The machine of claim 15, wherein the controller includes an application specific integrated circuit.
- 37. The machine of claim 15, wherein the controller includes discrete circuitry.
- 38. Software for use with a packaging and inspection machine that inspects a digital image of a composite tape, the machine including a camera operable to acquire the digital image and a processor in communication with camera, the software being executable by the processor to perform the steps of:
receiving the digital image of the composite tape; analyzing the digital image for defects; and if a defect is found, generating an output indicating a fault condition.
- 39. The software of claim 38, wherein said analyzing step includes the steps of:
defining a portion of the digital image including the first seal track; dividing the portion of the digital image into a plurality of segments; analyzing each segment of the seal track digital image; and assigning a passing or failing grade to each segment.
- 40. The software of claim 38, wherein said analyzing each segment step includes the step of determining whether the seal is continuous within the segment; and wherein said assigning step includes, the step of assigning a failing grade to the segment if the seal is not continuous within the segment.
- 41. The software of claim 39, wherein said analyzing each segment step includes the step of calculating the width of the seal track within the segment; and wherein said assigning step includes the steps of comparing the width to a minimum width and assigning a failing grade to the segment if the width is below the minimum width.
- 42. The software of claim 39, wherein said analyzing each segment step includes the steps of determining whether the seal is continuous within the segment and calculating the width of the seal within the segment; and wherein said assigning step includes the step of assigning a failing grade to the segment if the seal is not continuous within the segment or if the width is below the minimum width.
- 43. The software of claim 39, wherein said analyzing step includes the steps of:
determining a number of consecutively-failed segments for the portion of the digital image; and comparing the number of consecutively-failed segments to a defect tolerance.
- 44. The software of claim 38, wherein said inspecting step includes the steps of:
finding an edge of the carrier tape within the digital image; and defining an area of the digital image where one of the seal tracks is likely to be based on the position of the carrier tape edge.
- 45. The software of claim 44, wherein said finding step includes using a gradient-based edge tool to find the carrier tape edge within the digital image.
- 46. The software of claim 44, wherein said inspecting step further includes using a gradient-based edge tool to find seal track edges within the predicted area where one of the seals track is likely to be.
- 47. The software of claim 38, wherein said analyzing step includes the steps of:
creating robust line equations for the first and second seal tracks; calculating the distance between the first and second seal tracks based on the equations; comparing the distance between the seal tracks with an acceptable value; and determining whether there is a defect in the seal tracks spacing.
- 48. The software of claim 38, wherein said analyzing step includes the steps of:
calculating a robust equation for an edge of the carrier tape; calculating a robust equation for an edge of the cover tape; using the equations to determine the distance between the edges; comparing the distance between the edges with an acceptable value; and determining whether there is a defect in the spacing between the edges.
- 49. The software of claim 38, wherein said analyzing step includes the steps of:
calculating a robust equation for an edge of the carrier tape; calculating a robust equation for the first seal track; using the equations to determine the distance between the carrier tape edge and the first seal track; comparing the distance between the carrier tape edge and first seal track with an acceptable value; and determining whether there is a defect in the spacing.
- 50. The software of claim 38, wherein said analyzing step includes the steps of:
positioning first, second, third, and fourth boxes in the digital image in the nominal positions of a carrier tape edge, a cover tape edge, the first seal track, and the second seal track, respectively; performing a gradient-based edge tool function on the data within the first, second, third, and fourth boxes to formulate a robust line equation for each of the carrier tape edge, cover tape edge, first seal track, and second seal track; using the robust line equations to calculate the spacing between the edges of the carrier tape and cover tape; using the robust line equations to calculate the spacing between the cover tape edge and the seal track; using the robust line equations to calculate the spacing between the first and second seal tracks; and comparing the calculated spacings to nominal values; and determining whether there are irregularities in the cover tape and seal track positioning.
Parent Case Info
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/297,853, filed Jun 13, 2001.
Provisional Applications (1)
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Number |
Date |
Country |
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60297853 |
Jun 2001 |
US |