What Problems do Optical Inspection Systems Solve?

June 2022

What Are Automated Optical Inspection Systems and What Problems Do They Solve When Integrated Into Automated Machinery?

The automation industry is in a period of unprecedented growth. More and more businesses are experiencing the benefits of industrial automation.

Is it time to join them?

An automated optical inspection system can significantly improve the quality control process for manufacturing. Machine vision can solve the problems associated with manual inspections.

Learn more about automated optical inspection systems and the difference they can make in the production process.

What Is an Automated Optical Inspection System?

Optical inspection is a method of quality control. It looks for defects during the manufacturing process. It gathers data that technicians can use to identify the cause of product flaws.

Manual visual inspection was the traditional industry standard. An inspector looked at each component to determine if defects were present.

Automated optical inspection systems detect flaws and perform assessments without human intervention. They use machine vision and deep machine learning.

An automated optical inspection system can go beyond identifying errors. It can recognise trends and make predictions.

Top Machine Vision System Suppliers

The two largest machine vision system suppliers are Cognex and Keyence. Other leading companies include Omron and Basler. Smaller manufacturers like Wenglor also offer innovative solutions.

Types of Vision Systems

An automated optical inspection system has three basic parts: image acquisition, lighting, and programming. Systems vary depending on their application.

They range from systems with a single camera to multi-camera systems that perform several inspection tasks. They can be an independent inspection station or a complete turnkey system. Vision systems can be categorised in several ways.

Area Scan vs Line Scan

Area scan and line scan are two methods for capturing an image. An area scan camera captures the image in a single frame. The width and height match the number of pixels on the sensor exactly.

Area scan cameras are easy to set up and align. They are not well-suited for applications where the target object is moving, though.

Line scan cameras build the image one pixel row at a time. Images with higher resolution are possible. Line scan cameras are well-suited for high-speed continuous applications.

They can create images of round or cylindrical parts without distortion.

1D, 2D, or 3D

Machine vision systems can create images in 1D, 2D, or 3D. Each technology has advantages for different applications.

1D Machine Vision

1D vision uses a line scan camera. It analyses the digital signal one line at a time. 1D vision is a good option for parts manufactured in a continuous process, such as:

• Paper
• Plastics
• Metals
• Other non-woven sheet or roll products

2D Machine Vision

2D cameras can use the area scan or line scan method. They create a two-dimensional map. The image does not include height information.

2D vision systems are common throughout the industrial automation industry. They can perform tasks like:

• Verifying features and position
• Checking dimensions
• Reading barcodes
• Verifying labels

2D vision systems are especially useful in high-contrast applications. They are also a good choice when the texture or colour of an object is important.

3D Machine Vision

3D machine vision systems use several cameras or laser displacement sensors. The cameras are in different locations to triangulate on the object. 3D vision systems create a highly accurate three-dimensional model.

3D vision systems can perform many tasks, such as:

• Measuring thickness, height, and volume
• Measuring holes, angles, and curves
• Detecting surface defects
• Picking parts from a bin for packing or assembly

A 3D system is well-suited for applications that need high precision while also allowing variation.

PC, Compact, or Smart Camera

Traditional machine vision systems are PC-based, and the complexity and cost can vary greatly, but more compact, simpler and less expensive options are also available.

PC-Based Systems

PC-based systems have an industrial computer that communicates with peripheral devices like cameras and lighting. They have high computing power. They are very flexible.

PC-based systems are ideal for complex applications with many inspection tasks. They can be more expensive than other options, though.

Compact Systems

Compact systems have less processing power than PC-based systems. They are usually sufficient for less demanding applications. They usually have a graphics card that acquires data and transfers it to a separate peripheral.

Compact machine vision systems are less expensive.

Smart Camera Systems

Systems based on smart cameras are the simplest. They work in combination with standard optics and lighting. They are easy to set up.

Smart camera systems are a good option for simpler applications. They have functionalities similar to traditional systems in a more compact form and simpler to program.

What Problems Does an Automated Optical Inspection System Solve?

Like other industrial automation solutions, an automated optical inspection system benefits the production process in several ways. Automated optical inspection provides faster and more reliable examination.

Improve Inefficient Processes

Automated visual inspection is ideal for high-volume manufacturing. Manual optical inspection cannot keep up with the pace of modern high-speed production. Automation improves efficiency and productivity.

The production process can move faster.

Ensure Accurate Results

Human error is inevitable. Errors are especially likely in repetitive, detail-oriented tasks like visual inspection.

Industrial automation of visual inspection significantly reduces errors. Product quality is higher because the system does not miss defects. The manufacturing process has less waste and lowers costs because of fewer false positives.

Promote Continuous Improvement

Automated optical inspection systems provide data that can help you improve your production process. Dealing with the same product flaws over and over wastes time and money.

Data from the optical inspection system can show the root cause of a problem. You can make the necessary changes to avoid the same issues in the future.

Data from an automated optical inspection system improves your documentation and process control. You have digital records that are fully traceable.

Incorporating an Automated Optical Inspection System in Your Production Process

An automated optical inspection system makes your quality control process faster and more accurate. You can identify the causes of manufacturing issues and resolve them.

SP Automation & Robotics integrate appropriate vision systems into their solutions, ensuring machine process checks are performed at predefined and appropriate steps within the automated process.

We partner with the best visual inspection system providers in the UK. From a simple, intelligent vision system to a full-colour pixel camera recognition system, we will design the solution you need.

Contact us today to find the industrial automation solution for your quality control process.

 

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