Industrial Vision System Applications & Solutions
Automate and Control LTD bring you the Aiot4 brand of advanced Industrial vision systems. Our systems have overcome the traditional issues related to industrial vision utilising ML and AI taking out the human error side of system setup with intuitive vision tools. Encompassing integrated intelligent lighting, cameras and controllers all coupled with world class latest generation algorithms in our easy to use software.
Contact2D & 3D Vision Inspection Video
Area Camera Vision Systems
Stamped character vision inspection
The stamped characters, which are bumpy, are inspected while ignoring the characters printed on the package.
Examples include
Pharmaceutical packaging, Toothpaste Cartons, Variable Data and Product Security Features
Package opening perforation presence inspection
Even if a pattern is present in the background, inspection can be
performed since it is possible to obtain the shape alone.
Chip inspection on a metal surface
Factors such as remaining cleaning agent, dirt, and minor hairline
fractures are cancelled so that only deep defects such as scratches
and chips are detected.
Printed character inspection on a film surface
Glare, which affects inspections negatively, is eliminated to enable
stable inspections.
Metal casting surface carved seal inspection
From a random casting surface, the carved seals with greater
concave-convex information are emphasised.
Chip inspection on a printed surface
Images in which only the chips are extracted are created without
being affected by the complex printed background.
Packaging Integrity for the Food Industry - Heat seal width inspection
The roughness information of sealed parts, for which changes are difficult to detect by means of colour or shading, are captured and extracted. This system perfectly inspects heat sealed packaging such as tray sealing integrity inspection for ready meals and vertical bags sealers.
Tape presence inspection
Even when unexpected specular reflection occurs due to workpieces
being tilted, the glare can be cancelled, which makes it possible to
perform stable inspections.
Foreign particle detection on the inside of a container
Conventional binary processing would
not be able to detect the foreign particles
as there is very little contrast between the
particles and the dark portions of the
container, however, defect inspection tool
can compare the differences with the
surroundings, allowing reliable detection
of only the foreign particles.
Cancel unwanted shading on metallic curved surfaces to enable stable machine vision performance
Cancels uneven lighting produced by curved surface areas on cylindrical workpieces and
extracts only arbitrary flaws such as bright or dark defects.
Surface roughness on plastic products canceled for stable flaw identification
Detects only long, line-shaped flaws while ignoring the surface roughness.
Micro-flaws are canceled and only the desired flaws are stably detected
Uneven texture on metal workpieces canceled for stable flaw identification
Uneven textures unique to forged parts are canceled and only deep flaws generated by
dents are detected.
SCRATCH DEFECT INSPECTION
Eliminates noise information within the inspection region and only highlights linear information. This filter is particularly effective for linear defect inspection for workpieces having rough surface
conditions.
PLASTIC MOULD DEFECT DETECTION
>Our algorythems cancel shading or uneven brightness occurring on the workpiece surface to optimize images for inspection. Even if shading conditions change every time, this filter corrects images in real time to only extract defective sections.
AUTO LEARN VISION SYSTEM UTILISING SUBTRACTION
Compares the current image with a previously registered master image to extract sections that differ. It is also possible to take individual differences in non-defective workpieces into account and adjust how much differences should be recognized as defective.
WIDTH INSPECTION FOR A WELDED PIPE SECTION
Blurs the inspection region to remove a significant amount of fine background patterns or noise. This filter offers more stable inspection by intentionally blurring images to eliminate aspects that need not be inspected. Edges are detected in areas outside the welded section due to hairlines on the metal surface or
sputter deposited on surrounding areas.
The blur filter allows for stable width measurement by eliminating unnecessary featured points other than the welded section.
Edge defect inspection for burr and flaw inspection
This tool extracts a profile from the edges of a workpiece and recognizes the sections that show a large difference from the profile such as burrs or flaws. In addition to circles
and straight lines, ovals and profiles with complex shapes consisting of free curves are supported, based on edge information of up to 5000 points.
With a variety of parameters, certain defects can be distinguish from others. Settings can be optimized according to inspection category, such as
+/- from the reference line (burrs/flaws) and width/size that exceeds a threshold.
AUTO-TEACH INSPECTION TOOL
An inspection tool that learns what a good part is. The Auto-Teach Inspection Tool uses the camera to learn variations and individual
differences that exist in the good parts and recognizes those that fall outside these
parameters as defective parts. This algorithm eliminates unstable elements to
successfully guide on-site inspection. Settings are performed just by running good
parts, and eliminates the conventional need for highly-experienced vision
integrators and complicated programming. This is an inspection tool that makes it
possible for anyone to achieve and maintain a stable inspection.
Line Scan Camera Vision Systems
CYLINDER INSPECTION AREA CAMERA
EXAMPLE: VISUAL INSPECTION OF A GEAR
With an area camera
Captures a single area of the part in one image. Since it is a
round part, inspection is difficult due to the radius and uneven
lighting. Also, multiple overlapping inspections need to be
performed to analyse the entire circumference.
CYLINDER INSPECTION LINE SCAN CAMERA
EXAMPLE: VISUAL INSPECTION OF A GEAR
Captures the image one line at a time and then expands the
entire circumference into one single image. Lighting is very
uniform and the inspection of the whole part is done in one
process. Inspection accuracy is greatly improved and processing
time is reduced.
OTHER APPLICATION EXAMPLES:
Defects on blow moulded parts
Before blow moulding, the entire opening and body of the part can be inspected in one image when the part is rotated.
Visual inspection of a bearing
Achieves the visual inspection of curved surfaces, which is difficult to perform with an area camera, by capturing stabilised images with even lighting.
Visual inspection of a roller
Defects on the surface of long metal rollers can beinspected with high-accuracy using one or two linescan cameras.
Line Scan Camera Vision Systems Foil Film Inspection
VISUAL INSPECTION OF ALUMINIUM FOIL WITH AREA CAMERA
When using an area type camera to inspect the entire
workpiece, it is difficult to obtain even lighting over the whole
surface. Also, the pixel array in the XY direction is limited by
the camera so multiple image captures may be necessary to
secure a resolution that can satisfy the application.
VISUAL INSPECTION OF ALUMINIUM FOIL WITH LINE SCAN CAMERA
When using a line scan camera, only the X direction pixel array
is fixed based off the camera while the Y direction is expanded
according to the part movement direction. Much larger pixel
arrays are possible with up to 8192 x 8192 pixels (or 4096 x
16384) in one single image. Very high detection accuracy is
realised in one inspection process.
OTHER APPLICATION EXAMPLES:
Visual inspection of a roller
Defects on the surface of long metal rollers can beinspected with high-accuracy using one or two linescan cameras.
Visual inspection of lead frames
Visual inspection of the surface of plated lead frames and plate position inspection are accurately performed during transfer.
Visual inspection after printing electrodes
By using line scan cameras with line lights for targets that require a wide-field, uniform lighting is achieved and high-definition inspection is possible.
Dimensional inspection of a rubber sheet
Width measurement, which typically requires 2 area cameras on each edge, is performed with a single high resolution line scan camera, resulting in increased accuracy and reductions in cost.
Inspection of pinholes and dirt on a sheet
Achieves visual inspection of foreign objects, flaws, and pinholes on film or sheets on a high-speed production line.
Visual inspection of stamped metal material
High-speed inspection is performed on pressed parts that are continuously punched. High-speed inspection at resolutions that are much higher than conventional devices is achieved, leading to improved inspection
accuracy.
accuracy.
WORLD’S FASTEST! 3D INSPECTION & MEASUREMENT VISION SYSTEM
SAMPLING AT 64000 PROFILES/SEC
The LJ-V Series has realized the fastest sampling speed in the world for 2D laser measuring instruments.* This makes it possible to measure high definition laser profiles of products on high-speed manufacturing lines without missing a single one. For example, the LJ-V Series can measure targets moving at 6.4 m 21.0’/s with a 0.1 mm 0.004″ pitch. The LJ-V Series does not miss a single abnormal or defective part.
* According to KEYENCE’s investigation (as of June 2013)
Height, width, position, cross-sectional area, and volume can all be inspected in one system.
Target displacement can also be corrected in real time.
Low contrast between target and background? - Problem solved!
With an area camera, stable character recognition is difficult due to variations in background conditions and poorly defined stamped edges. Using 3D height information, the background can be distinguished clearly from characters
OCR FOR STAMPING ON A CAST COMPONENT
Defects missed on curved surfaces? - Problem solved!
With an area camera, dents cannot be detected due to shading caused by complicated curved surfaces or concaved/convexed shapes. Such detection becomes possible by extracting height deviation from free-form plane information.
FLAW/DENT INSPECTION FOR A PLASTIC MOLD
