Design and development of an Automatic Optical Inspection (AOI) system support based on digital manufacturing

Abstract

Visual inspection of components, subassemblies and final products is an essential step to ensure the quality control of ready-to-market electronic components. In many manufacturing plants, including Bosch Car Multimedia S.A., typically automated systems for automatic optical inspection (AOI) are implemented at several workstations to perform visual verification and validation in between critical production tasks. At Bosch Car Multimedia S.A., the AOI system includes a metallic support frame that accommodates a series of components for the function of AOI. The support frame is attached to a robotic arm for controlled movement. As the AOI is a rather fast-moving process, deformation of components may occur during monitoring due to the high acceleration of the robotic arm while operating. In addition to this issue, the existent AOI system includes a high number of components and connections which increase complexity for assembly and disassembly operations. This paper presents the redesign for enhanced performance and functionality of a AOI metallic support frame by resourcing to the generative design (GD) exploration method. Furthermore, additive manufacturing technology, based in selective laser sintering (SLS) of polymeric powders, was used for the production of a new lightweight and reliable version of an AOI support frame. The alternative AOI support frame configuration consists of a single consolidated polymeric component that enabled an overall weight decrease above 30% and a reduction of main components and total number of parts of approximately 89% and ~77%, respectively.