Market Application Background
In modern electronic products, power inductors are key components in power management and signal processing. Among them, NR (amorphous alloy) power inductors are highly favored due to their superior electrical performance and high energy conversion efficiency. However, the quality of the electrode surfaces directly affects the inductor's performance and reliability, making efficient and accurate detection crucial. Traditional visual inspection methods are often inefficient and struggle to identify complex defects. With the rapid development of artificial intelligence technology, AI visual appearance inspection technology provides an effective means to solve this problem.
▲ NR (Amorphous Alloy) Power Inductor ▲
Pain points of traditional vision solutions
Currently, traditional vision solutions used in the market typically have the following problems:
● Insufficient precision: It is difficult to effectively identify minute defects on the electrode surface (such as minor scratches, stains, oxidation), which directly affect the inductor performance but are often overlooked.
● Lack of standardization: The lack of unified testing standards leads to inconsistent results, causing fluctuations in product quality and damaging customer trust.
● Poor adaptability: Traditional solutions are unable to respond quickly to new defects caused by changes in materials and processes, resulting in delayed and blind detection.
Advantages of Positive Motion AI Visual Appearance Inspection Solution
To address the issues existing in current market solutions, ZhengYun has launched an AI visual appearance inspection solution with the following advantages:
● High-efficiency production: Automated testing processes significantly improve production line efficiency.
● Accurate and reliable: Based on deep learning algorithms, it can accurately identify minor defects, significantly reduce the false negative rate, and ensure stable quality.
● Real-time control: Dynamic monitoring of the production process enables immediate detection and handling of defects, effectively reducing the output of defective products.
● Convenient and easy to use: Equipped with a fully Chinese operating interface and flexible adjustable parameters; supports three-level permission management (operator/technician/engineer); provides detailed operation manual and technical support, and enjoys one year of free maintenance and upgrade service.
01. Application of Positive Motion AI Vision Appearance Inspection in NR Power Inductor Quality Control
Design of NR power inductor quality control scheme for positive motion technology
System Components
The AI visual appearance inspection system consists of five core modules that work together to form a complete intelligent inspection closed loop:
1. Image acquisition module
It integrates industrial-grade imaging components such as industrial cameras, lenses, and light sources to accurately capture image data of product surfaces.
2. AI Image Processing Platform
Based on deep learning algorithms, the acquired images are processed and analyzed in real time, efficiently performing defect identification (such as scratches, cracks, stains, and holes) and high-precision size/shape measurement tasks.
3. Model Training Module
It provides a complete set of tools from data annotation and model training to deployment and validation, enabling users to independently build customized detection models.
4. Result Output Module
It provides real-time visualization of the detection results and can interact with the production control system.
5. System Operation and Maintenance Management Module
Monitor system operation status and provide functions such as parameter configuration and fault diagnosis.
AI visual inspection process implementation
The system is equipped with a high-resolution industrial camera and a dedicated light source, enabling it to capture high-definition images of passive components. Upon receiving a trigger signal, the system activates the light source and acquires images via the industrial camera. The acquired images are then analyzed and inspected, and the inspection results are output.
The system's interface is simple and intuitive. Operators can modify parameters, trigger detections, and view results using a touchscreen or mouse and keyboard.
▲ Cross-sectional view of the test ▲
Core functions of AI visual appearance inspection system
1. Precise defect identification
Comprehensive inspection of product surface defects such as scratches, cracks, stains, and holes, and precise recording and analysis of key information such as defect type, location, and size, effectively preventing defective products from leaving the product.
2. Dimension Measurement
It automatically measures key dimensions of products such as length, width, height, and diameter, compares them with standard data in real time, and quickly determines the product's dimensional compliance.
3. Shape consistency judgment
Precisely inspect the geometric features of the product (such as roundness, straightness, and flatness) and compare them with standard shapes to ensure that the product shape meets the requirements.
4. Color quality control
Accurately detect color differences and color deviations in products, compare them with standard color sample data, and ensure batch-to-batch color consistency and quality.
5. Intelligent Data Management
Real-time storage, querying, statistics, and analysis; production inspection reports and quality analysis reports provide strong data support for production process monitoring and quality control.
Test case illustration
Solution hardware configuration
02. AI Visual Appearance Inspection System
Zhengdong Technology's AI-powered visual appearance inspection system, based on machine (deep) learning technology, enables automated and high-precision inspection of product appearance. This system can efficiently identify various surface defects (such as scratches, cracks, stains, and holes) and accurately measure key appearance features such as product dimensions and shape. It boasts significant advantages such as fast inspection speed, high accuracy, and good stability, and is widely used in quality control processes across numerous industries including electronics, automotive, machinery, food, and pharmaceuticals.
Technical support
● Stringent acceptance standards: Before system delivery, it must pass multiple tests, including mixed package verification, load testing, and no less than one month of commercial trial operation, to ensure equipment stability and a test pass rate of ≥99.8%.
● Full-service support: We provide one-stop services such as installation, commissioning, and technical training to help customers seamlessly connect and quickly put their products into production.
