Case Study | Revealing Microscopic Defects: Optimizing High-Precision Inspection for Rotary Cutting Machines

01 Introduction

The "micron quality inspection" on high-speed production lines was once a recognized bottleneck in the die-cutting industry. Today, the rotary cutting machine solution equipped with INSNEX macro camera is rewriting this understanding.

02 Customers

The client company is the world's leading core supplier of AI terminal hardware. The company mainly produces precision functional parts, structural parts, charging modules, wireless charging modules, etc. The products are widely used in consumer electronics, automobiles, industry and other fields. Its core customers include world-renowned technology companies such as A Company, H Company, and T Company, and have established long-term and stable cooperative relationships with many industry giants.

03 Challenges

As the core supplier of 3C industry's head end customers, the customer's keyboard glue die-cutting production line is facing the extremely stringent final test:

1. Space Restrictions:Installation space inside a rotary cutting machine is extremely limited, leaving no room for conventional line-scan cameras.

2. Various materials:Defects and dimensions must be inspected simultaneously across materials including blue film, black adhesive, graphite and aluminum foil. This makes imaging much more demanding, while end users require 100% detection with no missed defects.

3. Strict accuracy:The customer requires 0.01mm inspection accuracy. A 0.05mm gap in the black adhesive can cause electrical continuity failure, while burrs along the blue film edge can lead to product rejection.

Figure 1. Schematic diagram of customer rotary cutting machine equipment

04 Solution

In order to respond to the extreme needs of 3C leading customers, the company's engineering team plans to install the 100% online vision system to reduce manual inspection hours and production costs, improve the yield rate of the production line, and avoid the risks of leaks and customer complaints caused by manual inspections. At the same time, in order to respond to the rapid replacement needs of different customer products in the 3C industry, it is necessary to design a standard vision system that takes into account both "small space" and "high-precision" inspection.

Recommended by industry partners, INSNEX macro cameras have entered the customer's company's selection vision due to their performance advantages in achieving high-precision imaging in a small space.

1. Millimeter Space Revolution

90mm ultra-thin body +15mm macro imaging: reduces the space required by 70％ compared with conventional cameras and lighting, fitting directly into the rotary cutting machine outlet.

2. Micro-scale distortion-free imaging

The 1800dpi CIS delivers 0.014mm resolution. Its 1:1 imaging eliminates edge distortion for more accurate dimensional measurement.

3.2.5D presents relative height

Using time-multiplexed strobing and a photometric stereo reconstruction algorithm, the system renders small defects such as pits and bumps on aluminum foil and blue film in black and white respectively. Scratches show height variations, whereas contamination does not, enabling accurate classification and improving inspection accuracy.

Figure 2. On-site installation of an INSNEX 1800dpi macro camera in a rotary cutting machine

05 Customer Benefit

1. Accurate inspection:The accuracy rate of black adhesive detection is 99.98 %, and the customer complaint rate of conduction failure is significantly reduced;

2. Zero missed detection:The imaging accuracy reaches 14μm, and the detection rate of blue film and aluminum foil defects reaches 100 ％. Even small flaws cannot escape the "eyes";

3. No machine modification:The macro camera can be deployed directly with 0 modifications to the rotary cutting machine, reducing space requirements by 70%.

06 Customer Reviews

"A Company's orders cannot tolerate 0.1% errors! INSNEX's macro cameras not only allow us to pass the most stringent tests, but also enhance customer satisfaction with us."

--Customer company quality engineer

“We went from initial doubts to real confidence. The macro camera solved a major inline inspection challenge within the machine’s very limited space!”

--Visual engineer of client company

About Us

INSNEX was established in 2017. It has long been deeply involved in the field of visual defect detection. Relying on its profound industry application accumulation, it has continuously explored and iterated advanced imaging products that "make defects clearer", and is committed to providing customers with a more convenient defect imaging experience.

LineX series macro line scan cameras are All-In-One imaging solutions created by INSNEX for small space and high-speed line scan detection scenes. This series of products has macro imaging, non-splicing design and low distortion performance as its core advantages, allowing a clear view of subtle defects. Cooperating with the self-developed InsWorks software platform-integrating multi-dimensional algorithm tools such as 2D/3D/AI/ACI provides platform-level support for the development and deployment of complex inspection systems and comprehensively improves the accuracy and stability of defect detection.

At present, INSNEX products have been widely used in industrial fields such as lithium batteries, panels, semiconductors, photovoltaics, consumer electronics, 3D printing. The company has built a network of agents covering multiple regions around the world, bringing together the technical expert resources of more than ten professional partners, providing quickly responsive localized services to customers from all over the world, making line scan imaging and defect detection within reach.

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