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
3d vision lighting system
2d and 3d vision inspection cameras

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

stamper charecter vision inspection

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.
vision system AI Package opening perforation presence inspection

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.
vision inspection Chip inspection on a metal surface

Printed character inspection on a film surface

Glare, which affects inspections negatively, is eliminated to enable stable inspections.
Printed character inspection on a film surface vision system

Metal casting surface carved seal inspection

From a random casting surface, the carved seals with greater concave-convex information are emphasised.
Metal casting surface carved seal inspection

Chip inspection on a printed surface

Images in which only the chips are extracted are created without being affected by the complex printed background.
Chip inspection on a printed surface

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.

Heat seal width vision inspection tray sealing

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.
Tape presence inspection

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.
Foreign particle detection in a container

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.
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
Cancel surface roughness on plastic products

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.
Cancel uneven texture on metal workpieces

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.
SCRATCH DEFECT EXTRACTION

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.
Plastic mould inclusion detection

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.
Auto learn vision system AI ML machine learning

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.
WIDTH INSPECTION FOR A WELDED PIPE SECTION
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.
Dent detection Vision System
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.
low rez auto teach vision system caps
low rez auto teach vision system

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.
Area vision camera on gear inspection

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.
Line scan vision system camera gear industrial

OTHER APPLICATION EXAMPLES:

vision inspection cylinder bearings blow mould

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.
Area camera film inspection

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.
line scan camera foil film inspection

OTHER APPLICATION EXAMPLES:

inspection broken solar cells lead frames printed electrodes

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.

visual inspection rubber sheet pin holes film stamper metal material

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.

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.
worlds fastest 2d laser profile vision system
* According to KEYENCE’s investigation (as of June 2013)
3d vision system measurment and displacement
3d vision weld inspection
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
OCR FOR STAMPING ON A CAST COMPONENT inspection

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
FLAW DENT INSPECTION FOR A PLASTIC MOLD