A Guide to Choosing the Right Vision Based Inspection System

Introduction

Vision inspection systems harness automated digital imaging to fulfill crucial manufacturing tasks. These tasks encompass steps that require a high degree of precision such as quality control, sorting, and verification. Regarded as indispensable by industrialists today, the technology liberates production line staff for more strategic roles leaving the cumbersome work to the machines. Efficiency of the vision inspection system lies in their high-speed operation, which results in significant time and cost savings for manufacturers. These systems excel in rapid data processing and continually improve through artificial intelligence integration.

Furthermore, their capability to generate high-resolution images allows operators to scrutinize product defects with exceptional detail, contributing to less errors in the manufacturing process. In this article, we take a closer look at some of the vision-based inspection solutions and choose one that is right for you.

What Can Vision Based Inspection Systems Do?

Intelligent inspection systems are often equipped with multiple cameras, along with video and lighting features. These vision systems excel in measuring parts, verifying their correct positioning, recognizing shapes and more. Capable of high-speed measurement and sorting, they employ computer software to process captured images during the assessment process, extracting valuable data. Integration into production lines allows these systems to offer a continuous flow of information, ensuring real-time insights and efficient decision-making for enhanced operational precision.

Vision Based Inspection Examples

Here are some of the frequently used vision inspection systems in different industries:

1. Defect Detection and Classification: Detection defects is one of the most practical and common applications of the technology. It allows manufacturers to pick up product defects such as dents, bends, burrs or indentations that fall short of the quality controls.
2. Assembly Verification and Alignment: These systems use real-time optical data to assess proper alignment of components on the assembly line. They compare photos of real-time components on the line to predetermined templates to ensure alignment. It enables proper quality and reduction in defective pieces.
3. Optical Character Recognition (OCR): Characters such as alphabets, numbers, and codes on equipment and raw material can be read by vision-based systems. The technology allows effective asset tracking throughout the supply chain and improves other aspects such as inventory management, regulatory compliance, and counterfeit elimination.
4. End of Line inspection:  In End of Line inspection, vision-based Inspection systems employ cameras to swiftly scrutinize final products. They verify specifications, detecting defects or deviations. This efficient process ensures quality control and adherence to standards, reducing errors and enhancing the overall reliability of end products before they reach consumers.
5. Part Segregation: Vision-based Systems facilitate part segregation by swiftly and accurately identifying components and sorting them to the right station or identifying the whole using individual parts. Employing cameras and advanced algorithms, these systems ensure precise sorting and enhancing manufacturing efficiency by eliminating manual work.

Steps to Choose the Right Vision based Inspection System

While you may already know precisely the vision-based inspection you need for your industry, choosing the system goes well beyond the technology. It is equally important to choose the right partner/vendor who can deliver precisely what you need and ease the process of implementation. So here’s how you arrive at your solution before implementing vision based inspection:

1. The Inspection System Should be AI Driven

Legacy systems with simple programming have been the standard since visual-based inspection came into existence. However, AI reinforcement can fundamentally augment detection systems and increase the scope of error detections in production.

Visual-based Inspection, powered by deep learning algorithms, elevates the process by enabling the differentiation of parts, characters, and anomalies. This mirrors the capacity of human visual defect detection while leveraging the computational efficiency of a computer system. What’s more, unlike human operators who are subject to fatigue and experience, the AI system performs consistently.

2. Look for Specialization in Your Industry

Selecting a vision-based inspection system tailored to your industry can make a significant difference. Opting for a partner specializing in your specific sector is not merely a matter of cost; it is an investment in precision and expertise. Entrusting an experienced partner even if their service may entail a slightly higher cost, outweighs the risks of inexperienced handling.

A specialized partner comprehends the intricacies of your industry, foreseeing and addressing impending challenges with well-tailored solutions. The decision to engage an industry-focused expert ensures the perfect integration of vision-based inspection systems, enhancing efficiency and mitigating risks associated with subpar solutions.

3. Go Through Customer Reviews

When choosing a partner, go deeper into customer reviews, industry relevance, and challenges faced. Scrutinize project quality, services, timelines, duration, and costs comprehensively to avoid partnering with an unsuitable vendor. Assess their success rates and industry track record, examining their impact on businesses. Analyze their approach and ensure their solutions align precisely with your needs. Explore their client base from past and present to gauge their expertise and the breadth of industries they are able to serve. Additionally, verify if their technology is a good match for your requirements and does not fall short of any future upgrades you have planned.

4. Choosing for Employee Safety

When picking vision based systems for employee safety, it is crucial to look for a solution that offers more features than what you need. For instance, the system should incorporate face recognition to detect individuals not adhering to mask or safety gadget guidelines. It should also adeptly identify damaged equipment, such as compromised harnesses, helmets, or other PPE, facilitating prompt alerts and replacements. The system must also monitor adherence to safety protocols like social distancing, machinery standard operating procedures, and plant safety protocols, instantly alerting authorities in case of non-compliance.

Conclusion

By adopting vision-based inspection systems, industries can harness a powerful system for precision and efficiency in manufacture. The integration of advanced cameras, software, and artificial intelligence not only boosts defect detection but also finds application in end-of-line inspections and part segregation.Now that you know the different types of vision-based systems that exist and how to choose the right tech partner for your process, it is time to take the next step! Get in touch with our team and learn how sensing technology and automation can boost your productivity today!