The Challenger to Manual Inspection: The Quins Inspection System

Anyone who has worked with Automated Optical Inspection (AOI) systems knows the challenges involved, especially for small sized production runs with rapidly changing requirements. Traditional AOI systems often demand a significant amount of time for programming and debugging—time that can outweigh the benefits. Operating the AOI machines can be slow and costly in small production. As a result, manual inspection often proves more efficient and cost-effective for such cases. Medium and large production runs, of course, are a different story.

However, the Quins Inspection System offers an innovative alternative: an assistive optical inspection solution. This software-based optical inspection system eliminates the need for extensive programming and debugging. Instead, it uses a simple and intuitive approach: a reference image of a circuit board is scanned into the system, and the boards under inspection are compared to it. The system displays images of the reference board and the inspected board in rapid alternation on a screen, making it easy for operators to spot discrepancies.

How It Works

The operator scans a reference board into the system, which then divides the inspected board into smaller, manageable sectors. These sectors can be adjusted in size if necessary. The inspection proceeds methodically, sector by sector, ensuring no area is overlooked—an improvement over manual microscope inspections, which can easily miss details.

Quins does not use automation to detect anomalies; instead, it empowers the operator to identify discrepancies on the screen. Deviations are visually easy to spot because of the alternating image system. Quins rapidly switches between the reference image and the inspection image, making all deviations pop up clearly for the operator to identify. Surprisingly, this manual-like approach is highly effective, and because there is no need for time-consuming programming, the system is quick to set up and operate. Scanning a reference board requires no specialized skills.

Troubleshooting Made Easy

Quins is not only an excellent tool for quality control during production; it’s also a powerful resource for troubleshooting. If a PCB fails an electrical test, Quins makes it easy to identify potential issues such as missing components, incorrect polarities, solder bridges, or other assembly defects. By comparing the failed board against the reference image, operators can pinpoint faults quickly and efficiently, saving time in the repair process and reducing downtime.

Full Traceability of Inspection and Repairs

One of the standout features of the Quins system is its ability to document all inspection, defect, and repair data. Each detected issue is automatically logged into a database, complete with details like component identifiers, defect types, and visual evidence. The Quins Statistics module enables users to analyze this data for trends and performance insights, while the Quins Repair module ensures every correction or scrap decision is traceable. When boards are serialized, the entire process—from inspection to repair—is fully documented, meeting stringent traceability requirements for industries such as medical, aerospace, and defense.

Added Functionality

The system also integrates with placement coordinate files, enabling automatic documentation of detected issues. For every marked discrepancy, the system records details such as component identifier, name, defect type, and a reference image. These findings can be reviewed through the Quins Repair module, where operators can mark corrections or categorize boards as scrap.

All data is stored in a database, making it possible to generate comprehensive statistics through the Quins Statistics module. When boards are individually serialized, the system ensures full traceability of the inspection and repair process.

Advanced Features

For prototype or small production runs, the system allows the overlay of placement diagrams and placement coordinate files onto a scanned image of the assembled board. This enables the operator to verify correct component orientations and ensure all components are in place.

The Quins Tools module offers features for comparing Bills of Materials (BOMs) with placement coordinate files. Additionally, file filters can be configured to convert placement data from pick-and-place machines into a Quins-compatible format with just a few clicks.

Hardware Options

Quins offers a range of hardware options to suit various inspection needs:

• Quins Flex: A versatile tabletop workstation available in THT and SMD versions, differing in resolution and image size. It features fast image acquisition via a CMOS camera and specialized LED illumination for uniform lighting.
• Quins Pro: Designed for high-resolution imaging up to 600 dpi with 71.6 megapixels, covering a DIN A3 format. It includes specially developed LED lighting with 308 LEDs for shadow-free illumination.
• Quins Pro HR: For applications requiring even higher resolution, the Pro HR offers up to 4,800 dpi, allowing for detailed inspections. It maintains the same advanced LED lighting system as the Pro model.
• Quins Ultimate: A mobile and flexible inspection system that can operate independently or within a network, providing high-resolution images and a simple optical inspection environment.

Each model is designed to meet specific inspection requirements, ensuring that users can select the system that best fits their production needs.

Why Choose Quins in 2024?

In the seven years since this article was originally published, the demand for flexible, low-cost inspection solutions has only grown. With its intuitive interface, comprehensive features, and adaptability to various production needs, Quins remains a compelling choice for electronics manufacturers aiming to bridge the gap between manual and fully automated inspections.

Do you need more information? Head to the Quins website at www.quins.de.