PCB光电检孔机关键技术研究及其系统实现
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摘要
随着科学技术的发展,印刷电路板(Printed Circuit Board, PCB)的市场需求得到了飞速提高。PCB的加工质量在不断升级,其在线检测的精度和速度要求也不断提高。提高产品的出厂合格率,成为增强企业市场竞争力的重要手段。目前,我国在PCB检测的高端产品非常少,而国外产品价格昂贵,一定程度上制约了我国PCB产业质量的提高。
PCB光电检孔机是一种高度智能化的PCB钻孔自动检测设备。该设备提供了两种标准信息制作方法;可以对PCB钻孔的多种缺陷进行自动报错;检测精度很高,且处理速度非常快,能够保证对每一块出厂的PCB钻孔进行全面检测。
本文基于模块化、低成本、高性能的原则,开展了PCB光电检孔机系统的方案设计和具体实现。整套系统的论述主要分为系统结构设计、图像的高速采集和软件设计三个部分。
系统结构主要包括线阵接触式图像传感器(Contact Image Sensor,CIS)的高度调节系统,以保证对不同厚度的印制电路板能够成像清晰;解决了传送带的运行速度和图像采集必须保持同步的问题,能够满足不同传送速度下,采集到稳定的图像。
高精度的检测要求,使得采集的图像数据非常大。采用CameraLink高速视频图像传输模式,实现超大图像数据的快速传输。针对超长线阵CIS不同段的视频信号存在差异,利用A/D9822芯片的64级增益设置,采用闭环调节方法,能够自动设置各段视频信号的增益参数;上述方法提高了采集图像的质量,方便后续图像二值化处理。
本文提出了两种制作标准板信息的方法。一种是采用钻孔文件和扫描结合的制作方法;另一种是采用扫描合格PCB板的制作方法,本文提出的算法能够对合格板中极少漏检的缺陷圆孔进行参数修正。
超大图像数据的实时处理要求是对算法的最大挑战。本文提出了待测板和标准板的粗配准,精配准的算法,保证了图像配准的精度。经过大量的图像算法优化,提高了检测速度。本文提出了基于边缘方向角的自适应尺度的角点检测方法。利用PCB的4个轮廓角点关系,压缩参量空间,大大减少了Hough变换的直线拟合计算量。对快速Hough变换圆检测计算量进行了分析,提出了多尺度快速检测的方法。通过Hough变换圆检测和最小二乘圆检测相结合,提高了圆检测的抗噪声能力,保证了圆检测的精度。本文提出的算法不仅对圆孔,而且对异型孔也能检测。
上述算法和理论研究均成功地应用于PCB光电检孔机,该机器达到了第三代PCB孔径检测的技术指标,目前已经推向了市场。
With the development of science and technology, the market demand for printed circuit boards has been rising rapidly. The processing quality of PCB has been continuously upgraded and the precision and speed requirements of its online testing are also kept rising. Improving the ex-factory qualified rate of products has been an important means for an enterprise to enhance its market competitiveness. Currently, the numbers of China’s high-end products of PCB testing device are very small and the foreign products are very expensive, which limits the quality improvement of China’s PCB industry to some extent.
The PCB opto-electronic Holechecker is a highly-intelligent PCB drill-hole automatic testing device. It provides two information preparation methods for standard boards and may automatically report many defects of PCB drill holes. The testing precision is high, at a high processing speed, which ensures thorough testing of all ex-factory PCB.
In this dissertation, based on the principle of modularization, low cost and high performance, scheme design and concrete realization of the PCB opto-electronic Holechecker system are conducted. The structure of this dissertation is mainly divided into three parts, i.e.system structure design, high-speed image acquisition and software design.
The system structure design part mainly includes the height adjustment system of linear array contact image sensor (CIS), which ensures clear imaging of PCB of different thicknesses; it solves the problems of maintaining synchronism between operating speed of conveyor belt and image acquisition so that acquired images will not distort at different conveyance speeds.
High-precision testing requirements make the acquired images data quite large. The CameraLink is used to achieve high-speed transmission of ultra-large images. Aiming at the difference between video signals of different segments of CIS, 64-stage gain control of A/D9822 chip is adopted, to automatically set up gain parameters for different segments. The methods mentioned above have significantly improved the quality of acquired images and also facilitate the subsequent binarization processing of images.
Two methods of preparing standard board information are proposed: one is to adopt the preparation method of combining drill hole documents and scanning; the other is to prepare through scanning a qualified PCB board. The algorithm proposed in this dissertation may correct the seldom-missed defective round holes.
The biggest challenge to the algorithm is the real-time processing requirements of ultra-large images. Algorithms of approximate registration and accurate registration of testing PCBs and standard PCBs are proposed to ensure the precision of image registration. A large number of image processing algorithms are optimized in this paper to raise the testing speed. The adaptive scale corner detection method based on edge direction angle is proposed. 4 contour corner relationships of PCB are utilized to compress the parameter space and significantly reduce the computation load of straight-line fitting in Hough transform. The computation load of rapid Hough transform circle detection is analyzed to propose the multi-scale rapid testing method. By combining the Hough transform circle detection and the least squares circle detection, the anti-noise capability of circle detection is improved and the precision of circle detection has been obtained. The algorithm proposed herein can be used to test round holes as well as heterogeneous holes.
The algorithm and theoretical researches have been successfully applied to the PCB opto-electronic Holechecker and reached the technical index of the third generation PCB Holechecker, which has been promoted to the market.
PCB光电检孔机是一种高度智能化的PCB钻孔自动检测设备。该设备提供了两种标准信息制作方法;可以对PCB钻孔的多种缺陷进行自动报错;检测精度很高,且处理速度非常快,能够保证对每一块出厂的PCB钻孔进行全面检测。
本文基于模块化、低成本、高性能的原则,开展了PCB光电检孔机系统的方案设计和具体实现。整套系统的论述主要分为系统结构设计、图像的高速采集和软件设计三个部分。
系统结构主要包括线阵接触式图像传感器(Contact Image Sensor,CIS)的高度调节系统,以保证对不同厚度的印制电路板能够成像清晰;解决了传送带的运行速度和图像采集必须保持同步的问题,能够满足不同传送速度下,采集到稳定的图像。
高精度的检测要求,使得采集的图像数据非常大。采用CameraLink高速视频图像传输模式,实现超大图像数据的快速传输。针对超长线阵CIS不同段的视频信号存在差异,利用A/D9822芯片的64级增益设置,采用闭环调节方法,能够自动设置各段视频信号的增益参数;上述方法提高了采集图像的质量,方便后续图像二值化处理。
本文提出了两种制作标准板信息的方法。一种是采用钻孔文件和扫描结合的制作方法;另一种是采用扫描合格PCB板的制作方法,本文提出的算法能够对合格板中极少漏检的缺陷圆孔进行参数修正。
超大图像数据的实时处理要求是对算法的最大挑战。本文提出了待测板和标准板的粗配准,精配准的算法,保证了图像配准的精度。经过大量的图像算法优化,提高了检测速度。本文提出了基于边缘方向角的自适应尺度的角点检测方法。利用PCB的4个轮廓角点关系,压缩参量空间,大大减少了Hough变换的直线拟合计算量。对快速Hough变换圆检测计算量进行了分析,提出了多尺度快速检测的方法。通过Hough变换圆检测和最小二乘圆检测相结合,提高了圆检测的抗噪声能力,保证了圆检测的精度。本文提出的算法不仅对圆孔,而且对异型孔也能检测。
上述算法和理论研究均成功地应用于PCB光电检孔机,该机器达到了第三代PCB孔径检测的技术指标,目前已经推向了市场。
With the development of science and technology, the market demand for printed circuit boards has been rising rapidly. The processing quality of PCB has been continuously upgraded and the precision and speed requirements of its online testing are also kept rising. Improving the ex-factory qualified rate of products has been an important means for an enterprise to enhance its market competitiveness. Currently, the numbers of China’s high-end products of PCB testing device are very small and the foreign products are very expensive, which limits the quality improvement of China’s PCB industry to some extent.
The PCB opto-electronic Holechecker is a highly-intelligent PCB drill-hole automatic testing device. It provides two information preparation methods for standard boards and may automatically report many defects of PCB drill holes. The testing precision is high, at a high processing speed, which ensures thorough testing of all ex-factory PCB.
In this dissertation, based on the principle of modularization, low cost and high performance, scheme design and concrete realization of the PCB opto-electronic Holechecker system are conducted. The structure of this dissertation is mainly divided into three parts, i.e.system structure design, high-speed image acquisition and software design.
The system structure design part mainly includes the height adjustment system of linear array contact image sensor (CIS), which ensures clear imaging of PCB of different thicknesses; it solves the problems of maintaining synchronism between operating speed of conveyor belt and image acquisition so that acquired images will not distort at different conveyance speeds.
High-precision testing requirements make the acquired images data quite large. The CameraLink is used to achieve high-speed transmission of ultra-large images. Aiming at the difference between video signals of different segments of CIS, 64-stage gain control of A/D9822 chip is adopted, to automatically set up gain parameters for different segments. The methods mentioned above have significantly improved the quality of acquired images and also facilitate the subsequent binarization processing of images.
Two methods of preparing standard board information are proposed: one is to adopt the preparation method of combining drill hole documents and scanning; the other is to prepare through scanning a qualified PCB board. The algorithm proposed in this dissertation may correct the seldom-missed defective round holes.
The biggest challenge to the algorithm is the real-time processing requirements of ultra-large images. Algorithms of approximate registration and accurate registration of testing PCBs and standard PCBs are proposed to ensure the precision of image registration. A large number of image processing algorithms are optimized in this paper to raise the testing speed. The adaptive scale corner detection method based on edge direction angle is proposed. 4 contour corner relationships of PCB are utilized to compress the parameter space and significantly reduce the computation load of straight-line fitting in Hough transform. The computation load of rapid Hough transform circle detection is analyzed to propose the multi-scale rapid testing method. By combining the Hough transform circle detection and the least squares circle detection, the anti-noise capability of circle detection is improved and the precision of circle detection has been obtained. The algorithm proposed herein can be used to test round holes as well as heterogeneous holes.
The algorithm and theoretical researches have been successfully applied to the PCB opto-electronic Holechecker and reached the technical index of the third generation PCB Holechecker, which has been promoted to the market.
引文
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