Defect detection is production perfection

28 January 2014

Gemalto has improved productivity by using Keyence's CV-5000 vision system on its smartcard micromodules.

French smartcard manufacturer Gemalto produces microprocessor-based banking cards and SIM or UICC cards for mobile phones,  ePassports, smart identification cards, products for online authentication and contactless payment systems. To implement these solutions, remotely manage the applications, and store confidential personal information on these secure devices, the company also provides server software, consultancy, training, and a wide range of outsourced management services.

At the Gemenos site in France, the company checks that the protective resin overlay is correctly applied to micromodules. Dimensions, centreing, cleanliness, and whether the resin has been evenly applied without any overflow are also checked.

The resin is reinforced with fibres, dispensing defects can be a regular occurrence. The site produces 12,000 modules/ hour. As the smartcards are placed in 12 different positions, 12 modules are inspected at the same time. The inspection position is only 500mm away from the resin dispensing station. This allows early detection of defects and quick resolution of the issue, leading to a large reduction in waste.

Keyence's cameras are installed on six lines and operate 24/7. There are plans to add a seventh one soon.

The detection process is made more complicated by the fact that the resin used is transparent. Adding special lighting revealed differences in opacity, however. The images captured are processed in black and white with a resolution of 1.2Mpixels.  Keyence’s CV-5000 vision system handles all colour, B/W, single-camera and multi-camera applications. Its applications are dimensional measurement, positioning confirmation and visual inspection. The self-contained vision system allows one million pixels to be processed in 20.5ms. This processing power also makes it possible to perform multiple inspections and further enhance the reliability of in-process inspections thanks to its unparalleled repeatability (seven times higher than that of current standards) and many image processing tasks that optimize inspection accuracy.

CV-5000 Series models are controlled by a high-speed colour processing engine and a high-speed RISC CPU. Both are supplemented by two DSPs designed specifically for image processing.

All models use these four processors to achieve task specific processing and attain the fastest processing speeds possible – claimed to be twice that of the leading models available on the market. The system is also equipped with a double-buffer memory that allows it to capture the next image while an image is being processed. This enables an inspection time of about 16ms (about 3,700 parts/minute) even in non-interlaced reading mode. Connectivity is through discrete I/O, Ethernet, Ethernet I/P, USB and RS232 ports and the system can be integrated with PLCs or PCs.


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