inSpect Catalytic Converter / DPF Visual Inspection of Catalytic Converters / Diesel Particulate Filters

Advanced industrial vision technology tailored for inspecting catalytic converters and diesel particulate filters (DPFs) ensures precise detection of cell blockages and optical leaks as well as any deformations like chips, cracks, or gauges.

Catalytic honeycomb inspection

Quality control of the catalytic converters and DPF filters provides verifications on multiple levels. First and the most important is to check if every single cell and the entire product is within the necessary tolerances that provide 100% efficiency. From a process point of view, it is also a good checkpoint for controlling the cost management, as any deviations can be discovered early in the process and therefore limit the risk of producing imperfect products.

Geometrical properties inspection

Standards are often set as ideal geometric shapes, but inspecting each sample in real-time without causing production bottlenecks is challenging. Our expertise in 3D scanning, area scan cameras, telecentric lenses, and LED lighting, combined with sensor measurements, allows us to transition geometry inspection to inline 100% quality control. Using a 3D measuring machine, we can identify potential deformations and detect all chips or gauges, ensuring precise quality control.

Marking quality
inspection

To ensure traceability and genealogy, we utilize a range of laser and inkjet printing, labelling, and scanning applications for human-readable, linear, and 2D codes. When requested, we also conduct quality analysis (grading) of these codes, OCR, or other markings. Our system includes inline label applicators, printers, and inSpect cameras to accurately read and identify marks (DMC, OCR, or barcodes) in various positions, detailing their location, size, orientation, and contrast.

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360° view
covers all perspectives

Highly specialized vision inspection technology, with in-house designed machines and algorithms, tackles the most complex challenges. By employing a diverse range of technologies, we conduct thorough non-destructive inspection of all products within the production line. Our inspection process covers every possible angle, ranging from internal checks, looking for plugged cells or light leaks and coating depths, to surface checks, like edge chips, face gauges or surface cracks.

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Unparalleled speed
avoids any bottlenecks

Vision inspection stations should never be a bottleneck in the production, so special attention is given to the speed of all our solutions. Machines are designed in-house and therefore we take in control everything from the speed of handling system, time of image acquiring and processing, data analysis to reporting. inSpect can be optimized to reach speeds that can keep up with the production cycle time.

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Accuracy and precision
beyond industry standards

To achieve accuracy way above the industry standards we pay special attention to proper equipment selection and solution design driven by the challenge at hand. The existing solutions are constantly updated and designed with future upgrades in mind, understanding that every next generation of installed equipment can push the results and quality control to higher levels, so we strive for the outcome to be the best on the market.

Automated in-line visual inspection for catalytic converters /DPFs

The inspection system integrates seamlessly into any production line, ensuring high-quality assessment of all products while adhering to production cycle times, spatial constraints, and tolerance limitations. It provides instant response to optical leaks and cell blockages due to different production deviations, featuring fully integrated MES and SCADA systems to enhance operational efficiency and control.

Learn more

BASF
Boysen
Johnson Matthey
Tenneco
Umicore

High-resolution imaging with
collimated LED backlight

Using high-resolution line scan cameras, backlighting, and sophisticated image processing algorithms, inSpect detects cell blockages in catalytic converters and optical leaks in DPF filters. The system employs precise illumination techniques such as collimated LED light to strategically illuminate cells, ensuring the capture of even the smallest defects.

Acquired images undergo thorough analysis by advanced algorithms programmed to detect deviations from predefined criteria. Leveraging variations in light transmission or reflection, these algorithms accurately pinpoint irregularities within the structure.

This non-invasive approach ensures efficient identification of blockages and optical leaks crucial for maintaining product integrity in high-speed production environments.

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Multilevel inspection of each
cell and entire product

In-line vision quality control operates on multiple levels, ensuring comprehensive scrutiny of every passing substrate to guarantee 100% efficiency. The inspection covers each individual cell and the entire product, verifying that they meet the necessary tolerances. The system is adept at detecting blocked or partially blocked cells, optical leaks, partial cell leaks along the edges, and any surface anomalies.

To provide precise measurements of depth, area, and volume of each chip or gauge on a product, or simply notify of detected defects within requested cycle times we can also offer 3D camera systems, combined with deep learning technology. All inspection results, images, and parameters are stored, and automized reports are generated.

Real-time image
processing

To surpass industry accuracy standards, we adjust inspection system with the most suitable equipment for various quality inspection challenges. We incorporate the most suitable sensors, lighting systems, and handling mechanisms, complemented by innovative in-line integration. This synergy empowers us to analyse quite specific product defects during high-speed conveyor transfers and without the negative impact on the cycle time.

Surface parameter analysis and detection of irregularities are executed with image processing precision directly on the factory floor, achieving near-laboratory levels of performance with high-resolution technologies, problem domain specific algorithms and where needed, advances deep learning models.

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Maintaining production efficiency
with speed and precision

In addition to precision, the speed of each inspection is critical for maintaining production efficiency. To prevent bottlenecks, they must be completed in mere seconds, requiring accurate, precise, and rapid quality checks. Our visual inspection process operates swiftly, accommodating substrates of varying geometries and sizes.

Pushing efficiency further, our conveyors operate at speeds of up to 450 mm/s, with cycle times as low as 2 seconds per product. Within a mere 2.5-second cycle, we can inspect an impressive 160,000 cells per piece. Even with this high throughput, the entire inspection process — encompassing data acquisition, analysis, saving raw data, and communication — is completed before the next product arrives.

Seamless integration with production and its systems

The solution offers seamless integration into any production line. It features a user-friendly interface for vision software setup and a SCADA system for comprehensive control of the machine and peripheral devices, ensuring straightforward integration and start-up. This minimizes downtime during installation and commissioning, while also reducing start-up and tear-down times.

For site-specific integrations, the system’s modular design is a key advantage, facilitating the incorporation of additional functionalities and equipment. Furthermore, our design considers the potential for future technological upgrades, whether hardware or software. This allows for easy retrofitting of updates and potential upgrades without the need to change enclosures or undertake costly and time-consuming major mechanical modifications.

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Enhancing quality control
with automation

Implementing an automated inspection system offers numerous benefits. It establishes visual quality control standards, simplifies result auditing, and enables real-time rejection of faulty components. Acting as a crucial checkpoint for cost management, this system detects deviations in the production process early, reducing the risk of producing defective products. By removing human subjectivity from quality decisions, it promotes consensus among operators and meets the demand for precise quality control, particularly in areas such as surface, and foreign body detection.

We inspect every piece to quickly detect anomalies, ensure cost efficiency and ultimately reduce product recalls once on the market.

Additionally, real-time inspection capabilities and data feedback contribute to continuous quality control and process optimization, addressing issues such as reduced engine performance and increased emissions – emphasizing our dedication to environmental responsibility.

Reliable data tracking
with Data Matrix Codes (DMCs)

inSpect guarantees 100% reliable data tracking with laser-attached data matrix codes (DMCs). It supports high-speed in-line inspection where system transitions between continuous and indexed transit modes to achieve the required cycle time. It integrates in-line label applicators, green-dot markers, printers, and cameras to read marks (DMC, OCR, or barcodes) in multiple positions, specifying the location, size, orientation, and contrast.

Designed for multi-site implementation, our system offers a streamlined installation and management process, preserving modularity and minimizing downtime with a user-friendly interface. It supports software and hardware upgrades and allows additional equipment installation and retrofitting without significant mechanical work or relocation. Key benefits include instant response to labeling and marking failures, faster cycle times, in-line DMC code grading system with 100% of codes graded and an 100% pass rate in customer audits.

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Success Stories

Geometrical Propreties Inspection

Input Quality Control: Detection of Optical Leaks in Diesel Particulate Filters

In-line, non-destructive inspection system for canning process of catalytic converters and DPFs leveraging visual inspection and image processing.
1160756

Verifying washcoat application efficiency with visual inspection

End-of-line quality inspection system for the coating process of catalytic converters and diesel particulate filters using an advanced industrial vision system.
Coming Soon
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AI-powered 2D/3D visual quality assessment of extruded square and round CAT/DPF substrates

Visual inspection system designed for quality assessment of extruded CATs and DPFs implementing industrial vision technology and 2D and 3D measurements.

Technical Data

Inspection scope

100%

products inspected

Inspection cycle

< 2 sec

per substrate

Inspection rate

160,000

cells per piece

Scan resolution

16,000

pixels

Dimensional range

≤ 400

mm height / diameter

Data integrity

100%

reliable data tracking

Key Technologies

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Line scan camera

Line scan cameras capture a single line of an image with each snap. For a given field of view (FOV), a line scan setup provides superior spatial resolution, enabling smaller equipment footprints and more compact application designs.
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3D scanning

3D scanning inspects the geometrical tolerances of manufactured products, especially where critical deformation limits must be met. By analysing 3D point clouds, it identifies and measures deformities, comparing them to customer-defined tolerances.
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X-ray

X-ray imaging is essential for detecting subsurface irregularities. By combining industrial automation expertise with medical-grade X-ray technology, we provide advanced in-line X-ray solutions that meet high production rates, quality demands, and stringent safety standards.
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Deep learning

Deep learning, a rapidly advancing AI method, enhances machine processing capabilities to acquire, analyse, and learn within model frameworks. Its strength lies in the algorithms’ ability to identify patterns and logic in vast data sets.

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Frequently Asked Questions

inSpect Catalytic Converters/DPFs is equipped to examine substrates of diverse geometries, with dimensions spanning from 50 to 400 millimetres in height and 70 to 380 millimetres in diameter, ensuring comprehensive coverage of different sizes.
inSpect Catalytic Converters/DPFs boasts a cycle time as swift as 2 seconds per part. This rapid cycle time optimizes inspection efficiency, facilitating swift throughput and heightened productivity within industrial operations.
inSpect Catalytic Converters/DPFs efficiently manages data storage through internal storage mechanisms and offers seamless integration with customers' servers. This approach ensures enhanced accessibility, centralized data management, and streamlined analysis processes.
inSpect Catalytic Converters/DPFs achieves remarkable accuracy and repeatability, providing a 1% tolerance at 300 plugged cells in flowthrough parts. Its advanced capabilities include detecting plugged cells, identifying optical leaks, and detecting partially open cells in filters, ensuring consistent and reliable quality control.
Yes, the inSpect system is fully automated and seamlessly integrated with Master PLC, enabling complete control from the existing production line. Operators interact with the system through an intuitive HMI with Inspection software and SCADA interface, facilitating comprehensive control and monitoring capabilities.
The integration process of the inSpect system into a production line begins with assessing the specific needs of the customer. Based on these requirements, we determine the optimal layout for installing the system. Our approach utilizes the existing conveyors within the production line to facilitate the transition of parts downstream. Additionally, the complete system comes equipped with all necessary safety equipment and communication modules by default, ensuring seamless integration with the existing line.
inSpect Catalytic Converters/DPFs is equipped to examine substrates of diverse geometries, with dimensions spanning from 50 to 400 millimetres in height and 70 to 380 millimetres in diameter, ensuring comprehensive coverage of different sizes.
inSpect Catalytic Converters/DPFs boasts a cycle time as swift as 2 seconds per part. This rapid cycle time optimizes inspection efficiency, facilitating swift throughput and heightened productivity within industrial operations.
inSpect Catalytic Converters/DPFs efficiently manages data storage through internal storage mechanisms and offers seamless integration with customers' servers. This approach ensures enhanced accessibility, centralized data management, and streamlined analysis processes.
inSpect Catalytic Converters/DPFs achieves remarkable accuracy and repeatability, providing a 1% tolerance at 300 plugged cells in flowthrough parts. Its advanced capabilities include detecting plugged cells, identifying optical leaks, and detecting partially open cells in filters, ensuring consistent and reliable quality control.
Yes, the inSpect system is fully automated and seamlessly integrated with Master PLC, enabling complete control from the existing production line. Operators interact with the system through an intuitive HMI with Inspection software and SCADA interface, facilitating comprehensive control and monitoring capabilities.
The integration process of the inSpect system into a production line begins with assessing the specific needs of the customer. Based on these requirements, we determine the optimal layout for installing the system. Our approach utilizes the existing conveyors within the production line to facilitate the transition of parts downstream. Additionally, the complete system comes equipped with all necessary safety equipment and communication modules by default, ensuring seamless integration with the existing line.

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