Cost-Effective Piezo Inspection System for Touchscreens

CASE STUDY

Cost-Effective Piezo Inspection System for Touchscreens

Electronics Manufacturing

Client Challenge:

A touchscreen manufacturer needed a system to inspect the piezos around the perimeter of their touchscreens and measure the distance between each piezo and its alignment mark. The manufacturer sought a cost-effective solution that could achieve high measurement accuracy while minimizing expenses.

Our Solution:

We developed a piezo inspection system that leveraged the customer's existing Zenbot 2448 XY gantry system, repurposing it as the motion control platform for the inspection process. This innovative approach significantly reduced costs compared to purchasing a dedicated XY gantry system. The system integrated a Keyence vision system for image acquisition and analysis, a Gecko g540 4-axis control box for motion control, and Mach3 software for recipe creation and machine control.

Piezo Inspection System Features

01.

Motion Control

Repurposed Zenbot 2448 XY gantry system for cost-effective and precise movement of the camera and lighting.

02.

Vision System

Keyence XG Controllers and a 5-megapixel camera for image acquisition and analysis, achieving a measurement resolution of +/- 100 microns.

03.

Control System

Gecko g540 4-axis control box for coordinating the motion of the gantry system and camera triggering.

04.

Software

Mach3 software for creating and storing motion profiles and controlling the machine. Keyence software for vision algorithm development and analysis.

05.

Additional Components

Computer for software operation, electrical panel, and custom mounting bracket for the camera and lighting.

The Results:

The piezo inspection system successfully met the manufacturer's requirements for accuracy and cost-effectiveness. By repurposing the existing Zenbot CNC machine, Saber Engineering significantly reduced the overall project cost. The system achieved the desired measurement resolution of +/- 100 microns, ensuring precise inspection of the piezos and their alignment marks. The integration of the Keyence vision system and Mach3 software provided a user-friendly interface for recipe creation and system control.