| dc.description.abstract | This study developed an automated optical defect detection system aimed at inspecting the surface of cast metal objects, specifically focusing on golf club heads made from cast metal as the research subject. Initially, a light source configuration was designed, comprising a primary light source and a passive auxiliary lighting structure. The study utilized a directional light source to illuminate the target object for image capture, identifying the optimal imaging conditions to achieve the best image quality. Vision Assistant was employed as the primary tool for image processing, incorporating morphological operations, Laplacian filtering, binary segmentation, particle filtering, and defect analysis techniques to handle large volumes of image data.Additionally, LabVIEW was used to develop a virtual instrument (VI) to create a fast and detailed real-time inspection interface, providing precise defect information for foundries. On the hardware side, the study constructed a complete imaging system and a light pattern measurement device. The imaging system consisted of nine CMOS sensors arranged to capture different regions and was equipped with a golf club head clamping and positioning platform, along with a Python-developed positioning verification program to simplify operation and ensure positioning accuracy. To meet the requirements for lighting conditions, the system meticulously measured and recorded the light pattern, scattering, illumination angle, and intensity to ensure the consistency of lighting conditions during subsequent inspections.When inspecting micro-defects with an area as small as 0.022mm2, the system achieved a zero omission rate, maintaining a detection success rate of over 90% without any undetected defects. To meet the practical needs of foundries, the system integrated various functional modules, including defect count analysis, defect distribution analysis, and large defect detection, along with a classification system to facilitate subsequent defect handling or manual review. The entire inspection process takes approximately five seconds, requiring no adjustments to angles or light sources, significantly reducing the risk of human error during operation. This system effectively reduces the cost of optical defect detection while maintaining high convenience and functionality, providing an efficient AOI inspection solution for traditional foundries. | en_US |