1. Industry Pain Points
Traditional manual alignment for smart watch screen protective film lamination production lines brings multiple manufacturing challenges:
- Manual film application leads to offset, bubbles and edge warping, resulting in low product yield and high labor costs.
- Complex contours of watch screens and special-shaped films cannot achieve stable micron-level alignment by manual operation.
- No standardized coordinate output, unable to link automatic UVW alignment platforms or robotic arms for automatic deviation correction.
- Minor dimensional deviations between production batches cause poor manual adaptability and time-consuming model changeover debugging.
CKVision self-developed machine vision positioning system adopts dual-station image acquisition for smart watch screens and functional films. It outputs real-time X/Y/R rotation coordinates to guide automatic equipment to complete fully automatic precision film lamination, realizing unmanned precision fitting for mass production lines covering kids’ smart watches and adult smart watches.
2. Core Inspection Requirements of the Project
Inspected Objects
- Front screen of smart watch
- Special-shaped optical film for watch lamination
Vision Inspection Specifications
- Identify the outline of the watch screen frame, and output accurate X, Y and rotation angle R coordinate data in real time.
- Recognize the geometric features of special-shaped films, and synchronously output X, Y, R positioning coordinates.
- Link two sets of vision data with motion mechanisms to automatically compensate offset and guide high-precision film lamination.
3. Full Set of Vision Hardware Configuration
Station 1: Optical Path for Watch Screen Shooting
Total working distance of camera & lens: 300±20mm. The coaxial light source is 100±20mm away from the tested watch, performing vertical top-down imaging to fully capture positioning features including watch outer frame, screen and physical buttons.
| Hardware Category | Parameter Name | Value |
| Industrial Camera | Model | CK-S2000MI-6RS |
| Resolution | 5472×3648 | |
| Pixel Size | 2.4μm | |
| Image Color | Monochrome | |
| Calculated Accuracy based on Field of View | 0.014mm/pixel | |
| Industrial Len | Model | CK-AVS-M0121-U50 |
| Mount | 3mm | |
| Working Distance (mm) | 300 | |
| Theoretical Shooting Field of View (mm) | 70mm×45mm | |
| Coaxial light | Model | CK-HOP-800X-01 |
| Light Color | White | |
| Light Type | Coaxial light | |
| Working Distance (mm) | 105 |
Station 2: Optical Path for Film Shooting
Reverse optical path layout: the light source is close to film materials, and the camera is mounted at the bottom to vertically collect contour and buckle positioning features of special-shaped films, adapting to the installation space of film feeding platforms.
| Hardware Category | Parameter Name | Value |
|---|---|---|
| Industrial Camera | Model | CK-S2000MI-6RS |
| Resolution | 5472×3648 | |
| Pixel Size | 2.4μm | |
| Image Color | Monochrome | |
| Calculated Accuracy based on Field of View | 0.014mm/pixel | |
| Industrial Lens | Model | CK-AVS-M0121-U50 |
| Mount | 3mm | |
| Working Distance (mm) | 300 | |
| Theoretical Shooting Field of View (mm) | 70mm×45mm | |
| Coaxial light | Model | CK-HOP-800X-01 |
| Light Color | White | |
| Light Type | Coaxial light | |
| Working Distance (mm) | 100 |
4. Vision Imaging & Positioning Inspection Effect
1. Inspection Imaging of Smart Watch Screen
The algorithm automatically captures four-corner frame features of the watch to generate cross center reference coordinates. Multi-area frame selection enables stable recognition without interference from minor scratches or stains on watch cases, accurately calculating X/Y offset and rotation angle R.
2. Inspection Imaging of Watch Film
Multi-region feature matching is carried out for special-shaped films with buckles and notches to distinguish front/back and orientation of films, output complete coordinate data and prevent defective products such as reversed film direction and edge offset during lamination.
5. Core Capabilities of Self-Developed CkVisionBuilder Vision Software
- Code-Free Graphical ProgrammingDrag-and-drop algorithm tools without coding. Complete inspection workflows can be built in 4 steps: Image Acquisition → Contour Positioning → Coordinate Calculation → Data Output. On-site engineers finish debugging and model changeover within 1 day.
- Rich Preprocessing AlgorithmsBuilt-in more than ten image optimization tools including filtering, contrast enhancement, binarization, image equalization, adapting to image noise reduction for metal, film and plastic materials.
- High-Precision Contour Positioning AlgorithmSelf-developed multi-point template matching and edge extraction tools with sub-pixel positioning and tiny angle detection error, compatible with square, rounded and special-shaped watch products.
- Multi-Device Communication CompatibilitySupports TCP/IP, RS232 and I/O signal output, directly connecting PLC, UVW alignment platforms and 6-axis robotic arms to send X/Y/R compensation data in real time for closed-loop automatic deviation correction.
- Parallel Processing of Multiple ImagesSupports synchronous operation of up to 16 cameras, expandable to integrated multi-station solutions including screen inspection, film inspection and appearance defect re-inspection; supports program loop, branch logic adapting to tact time of automatic assembly lines.
- High Customization & ExpansionSupports secondary development and multi-task parallel computing, optimizing processing speed according to production line tact time to fit high-speed continuous lamination lines.
6. One-Stop Supporting Project Services
Full-cycle free technical support for 3C wearable production line customers:
- Free sample lighting test and professional vision inspection evaluation report delivery;
- Free on-site vision solution demonstration and hardware matching selection for equipment;
- Free training for customer technicians on software operation and graphical programming;
- Full assistance in production line process development and equipment debugging to guarantee stable mass production;
- Spare part replacement and on-site engineer emergency support under abnormal working conditions;
- Full-life free software upgrade and iteration throughout the whole solution lifecycle.
7. Core Advantages of the Solution
- Ultra-High Positioning Precision: 0.014mm pixel accuracy eliminates lamination defects such as offset, bubbles and edge warping to boost mass production yield.
- Integrated Dual-Station Design: One set of software synchronously collects two groups of coordinates for screens and films, reducing hardware investment of equipment.
- Stable & Adaptable Optical Path: Special coaxial light source eliminates reflection interference, and 20MP monochrome camera fits all types of watch appearance materials.
- Fast Model Changeover: Code-free graphical software enables rapid template input for new products, cutting debugging time by 80%.
- Fully Automatic Closed-Loop Control: Coordinate data directly connects motion mechanisms for automatic deviation correction and lamination, replacing manual labor and lowering production costs.
- Full-Cycle Technical Service: One-stop service covering sample testing, solution design, on-site debugging and lifelong software upgrade.