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Visual Inspection

AI-driven visual inspection systems for advanced defect detection and quality assessment.

Quality Assurance

Inspect the quality and abnormalities of the product in all stages of production, compare it with the norm by examining the shape, material composition, temperature, dimensions, colour, surface, homogeneity, granulation, marking, structure, and assembly integrity.

Poka – Yoke

Inspect the quality and abnormalities of the production process to identify and prevent potential errors by monitoring the presence, orientation, positioning, and identity of raw materials, semi-products, tools, and other production resources.

Process Management

Inspect, enable, and control the automated and robotized production process with pick and place, palletizing and depalletizing, automated machine tending, reject removal and other application-specific (peel off, etc.) robot and machine vision solutions.

Precision and consistency
at every step

Our industrial vision system guarantees precision and consistency, employing high-resolution imaging and automated processes to eliminate human error. Advanced technologies like endoscope cameras and X-rays perform non-destructive inspections ensure all products meet stringent standards without any damage. With 100% products inspected within the production line, our system offers comprehensive quality control, tailored inspections, and robust data management for seamless quality assurance across all batches

Product recognition
and positioning

Vision inspection solutions are designed to enhance product recognition and localization within robotic applications, significantly streamlining loading processes and accelerating cycle times. By integrating precise product handling with strict quality control measures, the system quickly identifies defects upon recognition, improving operational efficiency and reducing waste. Ideal for use in hazardous environments, our technology ensures operator safety while maintaining high standards of accuracy.

AI-driven defect
detection

The AI-driven approach leverages advanced multi-layer neural networks to harness the power of deep learning, enabling precise defect identification in complex product components. It excels in identifying anomalies throughout high-speed product manufacturing and mass production phases, adeptly categorizing visually similar products, even with diverse defect boundaries, and effectively identifying defects for rigorous quality and process control. The system scrutinizes cosmetic and surface defects, including unpredictable ones often overlooked.
BASF
Boysen
Continental
Johnson Matthey
Plastika Skaza
Tenneco
Umicore

Tailored industrial imaging
and inspection

We specialize in advanced imaging technologies, integrating line and area scan cameras, 3D scanning, X-ray, and deep learning for diverse industrial applications. Our expertise extends beyond standard deployments; we develop customized solutions using OEM, LabView and C# frameworks to meet specific requirements with the most suitable equipment and configurations.

Whether creating new vision systems or optimizing existing ones, our multidisciplinary team handles the most challenging demands, providing turnkey solutions for a wide range of industrial needs. Our industrial vision solutions combine cutting-edge software and hardware technologies tailored to fit any requirement, ensuring precision and efficiency in every application.

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Unleashing deep learning for
quality assurance

Artificial intelligence, especially deep learning, significantly enhances machine vision, overcoming challenges like ambient light, product variances, and positional changes that traditional sensors and cameras often face. By employing sophisticated multi-layer neural networks, our AI systems excel in various applications from sound and image recognition to defect detection in complex product components.

Utilizing the YOLO (You Only Look Once) model known for its speed and accuracy, our technology not only identifies defects during the production process but also discerns subtle discrepancies between acceptable and problematic items. This capability extends to high-resolution inspections of surface defects across diverse production environments, where it effectively manages the classification of defects and ensures strict quality control.

Distinguishing defects from
design features

Our systems adapt to varying lighting and part conditions, using high-resolution cameras and LED lighting to enhance defect visibility for thorough surface inspections. They inspect transparent elements using backlighting to detect anomalies in transparent windows. By analysing minute surface details, the AI model distinguishes between defects and inherent design features, and detects a wide array of defects, including inclusions, foreign bodies, cracks, fibres, and missing materials. This non-contact method ensures no contamination or damage during inspection, effectively identifying visual distortions, surface deviations and contamination.

The integration of deep learning AI elevates cosmetic inspection capabilities, allowing rapid and precise checks of surfaces, products, and components, ensuring rigorous quality control. Our library of defect templates, derived from client feedback, trains the model to recognize deviations within specified tolerance limits, improving diagnostic accuracy and reliability in detecting even the most unpredictable defects.

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High-accuracy surface inspection
with 3D scanning

Surface inspection utilizes advanced machine vision technology, integrating scanners and AI-enhanced area scan cameras to detect defects across various industries, including imperfections on fragile ceramic products without physical manipulation. This process preserves the integrity of the parts and controls their quality by analysing images as items progress through the production line.

For rigorous quality control, 3D cameras assess face gauges and surface contours, creating point clouds to compare against 3D models and pinpoint discrepancies in assemblies or cast pieces. AI-driven cameras, equipped with high-resolution imaging and specific lighting solutions, are strategically used to detect surface imperfections such as side cracks and surface scratches.

Visual Inspection Applications

Robot vision
inspection

When looking for a solution that replaces manual tending or loading, the only way to stay ahead of the game is robot vision. Robot applications with vision systems are needed to keep the operators safe in hazardous environments and improve their ergonomics. It can also improve cycle time, lower costs, and assure consistent quality when it comes to pick-and-place positioning or precise part assembly. Our experience, combining vision positioning equipment and several brands of robots (Mitsubishi, Yaskawa, Kuka, ABB, etc.), allows us to deliver a solution for any application need.

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. We have developed an in-line machine for complete control of blocked and partially blocked cells, or optical leaks on substrates with different geometry.

Surface quality
inspection

The surface of each product should be free of scratches, grease, or stains. While regular algorithms can detect flaws on monochrome backgrounds, they fail with patterned or wood-finish surfaces. To accurately identify surface irregularities on such backgrounds, we use advanced deep learning with neural networks, leveraging the latest software and hardware tools (CPUs, GPUs, FPGAs, etc.). The stability and sensitivity depend on the size of the base of input images. Usually, we train our system with at least 50,000 images with defined irregularities, and at least the same amount of images representing good quality products.

Geometrical properties
inspection

With our experiences in 3D scanning equipment (structured light pattern projection, 2D laser profiler, etc.), area scan cameras, telecentric lens, and different types of LED lighting (ring, dome, bar, etc.), by combining it with measurements from a variety of additional sensors, we are able to transfer the time-consuming geometry inspection to in-line 100% quality control and calibration with a 3D measuring machine. The results show if a certain 3D point is a potential candidate for deformation, not only determining bad quality parts, but also identifying all chips or gauges (with data such as depth, surface area, volume, location of deformation, etc.).

Sorting
application

Sometimes products cannot be sorted based on geometric properties or colour differentiation. In those special cases, we are using a different AI approach – deep learning – where the learning phase starts after system implementation. Usually, the goal is to differentiate between various product types. Often a few thousand pieces of each type are scanned with several repetitions. By default, around 98% reliability is achieved with an input of around 50,000 samples. It is important to note that reliability also greatly depends on the visual similarity of the parts. In general, machine sorting is several times faster than manual.

Assembly quality
inspection

End products are normally checked to make sure they are assembled properly, incorporating all needed pieces whether these are in their correct positions. Our part assembly quality control is mostly based on area scan cameras and pattern recognition. For most tasks, Keyence and Cognex tools are used and for more complex challenges, we develop our own algorithms and software.

Marking quality
inspection

For traceability and genealogy purposes, we implement various human readable, linear, and 2D code laser and inkjet printing, labelling, and scanning applications. If the process requires, we also perform a quality analysis of the applied codes, OCR, or other markings.

Key Technologies

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 better cycle time, smaller equipment footprints, and more compact application designs.

3D scanners

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.

X-ray

X-ray imaging is essential for detecting subsurface irregularities. By combining our 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.

Robot vision

Robotic vision systems enable precise product manipulation and inspection, operating in complex configurations to meet specific needs. They seamlessly integrate with various robots and detection systems via multiple communication protocols, enhancing efficiency and safety.

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.

Area scan camera

With extensive experience in implementing area scan cameras like Cognex and Keyence, we also develop custom modular solutions. We design turnkey systems, optimize existing machines, and choose the best approach and equipment for any requirement, unrestricted by supplier limitations.

Related Solutions

inSpect CAT / DPF

In-line vision inspection technology, using high-resolution line scan cameras, backlighting, and advanced image processing algorithms to identify cell blockages in catalytic converters and optical leaks in DPFs, as well as any deformations like chips, cracks, or gauges.

Electrical Tests

Automated in-line electrical testing systems ensure precise measurements and flawless connections between test probes and circuitry, even in the most intricate electronic components. These systems enable high accuracy and reliability in testing complex electronics.

Display Assembly

Building automated display assembly lines with in-depth expertise and state-of-the-art technologies to fully automate production, inspection, and testing. Covering simple to complex shapes and rationalising resource usage with operator- and maintenance-friendly design.

Artificial Intelligence

Applying AI models in machine and computer vision, acoustic detection, predictive maintenance, and predictive energy management enhances anomaly detection with high accuracy and real-time monitoring, identifying subtle anomalies that traditional methods might miss.

Mechanical Tests

In-line mechanical testing solutions suitable for fully automated systems with part manipulators, as well as for semi-automatic and manual testing environments. Testing systems, whether portable or integrated, are fully customized to meet the specific requirements of any production environment.

inSpect Bent Pin

In-line visual inspection technology for detecting bent pins in electronic connectors. It provides high-resolution images for precise measurement of pin heights and defect detection, mitigates reflections, and accommodates variability in pin dimensions and materials.

inSpect Fuel Cell

In-line visual inspection technology for high-volume roll-to-roll fuel cell production, essential for fuel cell quality assurance. It detects and analyses defects such as scratches, cracks, particles, and pattern irregularities in real-time while monitoring crucial process parameters.

inSpect Display Assembly

In-line visual inspection technology for monitoring defects, alignment, cleanliness, and overall quality of display assemblies as well as their software functionalities. We integrate system that use advanced vision algorithms to detect, sort, and position all assembly components.

Frequently Asked Questions

We prioritize the seamless integration of our vision systems into clients' existing production lines while striving to maintain the original process cycle times. The feasibility of integration depends on the specific requirements and the complexity of the existing system.
We aim to accommodate customer preferences for specific manufacturers whenever possible, aligning our solutions with equipment familiar to the customer. However, if a customer’s unique application requirements preclude the use of their preferred manufacturer, we actively engage with them to explore alternative options that best meet their needs while ensuring full support and integration.
We offer comprehensive after-sales support, recommending annual servicing and regular checks to ensure that the visual inspection systems continue to operate according to desired specifications. Additionally, we provide maintenance and support agreements to assist customers when issues arise that trained operators cannot resolve independently.
The proven methods such as Gage R&R and Measurement System Analysis (MSA) tests are consistently applied across different applications to ensure our systems meet the required tolerances. Additionally, where applicable, a calibration tool that closely resembles the product in production is used. This tool has predefined search points, allowing us to compare the measurement results from the system directly against the calibration tool's specifications, thus ensuring accuracy and compliance with production standards.
Our goal is to integrate our vision systems into clients' existing production lines with minimal impact on the overall cycle times. It is crucial that the visual inspection system does not significantly prolong production. In fact, when replacing manual quality control processes, it should ideally reduce the total cycle time by enhancing efficiency and accuracy.
Data from the visual inspection system is securely stored on dedicated servers, ensuring easy access and retrieval. Each piece of data is tagged and traced with unique identifiers, allowing for comprehensive tracking throughout the production process. Reports are generated automatically, detailing inspection outcomes, anomalies, and trends. These reports can be customized to meet specific regulatory or operational requirements, facilitating efficient quality control and decision-making. Where possible, we integrate with the client’s MES system to merge the specifications, control limits and tracking and tracing data into a holistic quality solution.
The accuracy of our visual inspection system is designed to surpass the precision of a human operator. This ensures a consistently high level of quality assessment, leveraging advanced technologies to exceed the capabilities of manual inspections.

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