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Detection of printed circuit board faults with FPGA-based real-time image processing

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Abstract

In the electronics industry, flawless manufacturing of printed circuit boards (PCBs) is essential for producing high-quality consumer electronics products. This paper presents a real-time image processing method that uses field programmable gate arrays (FPGAs) to detect missing components, which is a critical type of failure in surface mount devices (SMDs) on PCBs. FPGAs can perform multiple parallel operations on the same clock signal, allowing for real-time image processing through high-speed data transfer. The OV7670 image sensor is used to capture the PCB image. With the VHDL code embedded in the FPGA, a PCB image in RGB444 format and a size of 320 × 240 is taken from the sensor. During the image acquisition process, median and gaussian filters are used to remove noise components and improve image quality. Additionally, an LED lighting ring is used to further reduce noise components. User keys on the FPGA allow for filter selection, the selection of the number of filters, and the display of missing components on the VGA monitor. The missing component selection displays any missing components using soldered fields. This process aims to eliminate human error and achieve faultless production without manual inspection, saving time and reducing costs in the production process.

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Data availability

The datasets and codes generated during the current study are available from the corresponding author upon reasonable request.

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Funding

This study was not funded.

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Authors and Affiliations

  1. Department of Electrical and Electronics Engineering, Dogus University, Umraniye, Istanbul, Turkey

    Merve Aydın

  2. Department of Electrical and Electronics Engineering, Istanbul University–Cerrahpasa, Avcilar, Istanbul, Turkey

    Fırat Kaçar

Authors
  1. Merve Aydın
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  2. Fırat Kaçar
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Contributions

All authors contributed to the study’s conception and design. Material preparation, data collection, and analysis were performed by MA and FK. The first draft of the manuscript was written by MA and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Merve Aydın.

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Aydın, M., Kaçar, F. Detection of printed circuit board faults with FPGA-based real-time image processing. Iran J Comput Sci 6, 419–430 (2023). https://doi.org/10.1007/s42044-023-00149-6

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  • DOI: https://doi.org/10.1007/s42044-023-00149-6

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