Vision inspection systems incorporate automation, cameras, and sensors to speedily and reliably assist with process monitoring and product inspections in various applications. By integrating such systems into your production and assembly lines, it’s easier to ensure and maintain quality across your operation.
What Are Vision Inspection Systems?
Vision inspection systems rely on a combination of cutting-edge software, and vision systems to inspect goods during processing and production. They incorporate visual inspection automation technology and sometimes robotics to enhance tracking capabilities and quality assurance.
These systems have widespread applications, including but not limited to:
All-in-one smart cameras
High-speed controllers for 2D, 3D, and line scan camera systems
AI- and rule-based vision tools
Lighting, lenses, and peripheral systems for basic optimal image generation
Standard and laser microscopes
Safety laser controllers and scanners
Photoelectric, laser, and fiber optic sensors
Product and part marking and coding
As manufacturing and assembly operations become increasingly complex, dependable vision system inspections are becoming essential to effectively monitor and evaluate quality, trace and serialize products, and more.
Pros and Cons of Vision Inspection Systems
Vision inspection systems come with benefits and disadvantages, outlined below to help you determine if these systems are right for your application and operation.
Some of the advantages of using vision inspection systems include:
Optimized Efficiency: Automated inspections increase efficiency by replacing manual processes, allowing for faster inspections that still reliably ensure high-quality output throughout the production process.
Minimized Risk of Human Error: For successful manual inspection processes, a trained professional or team must perform the evaluations repeatedly, with an increased chance of missing damaged or flawed products as compared to cameras and sensors. Automated vision inspection systems optimize consistency and accuracy with minimal human intervention, maintaining better quality and keeping customers happy with defect-free products.
Cost Savings: Using camera systems for early defect detection will all but eliminate the need for later product rework and help prevent potential recalls. As a result, you benefit from considerable cost reductions in labor and materials over time, all while protecting your brand’s reputation.
Process Versatility: It’s easy to repurpose vision inspection systems for different applications and products, allowing for maximum versatility across your production or assembly line.
Increased Precision: Using advanced vision systems can allow stations to automatically perform critical measurements down to +/- 0.025mm, inspect for perpendicularity using coaxial lights and other inspections that a human just can perform.
While vision inspection systems offer numerous benefits, they also come with certain downsides to consider, such as:
Higher Upfront Costs: A vision system for quality inspections may result in lower long-term costs, but their initial costs tend to be considerably higher than those of a standard sensor. While such sensors can cost between $1,000 to $1,500 on average, expect to pay several thousand dollars or even tens of thousands for a full vision inspection system solution.
Need for Specialized Knowledge: The complexity of these systems makes them harder to install and maintain, requiring experts to carry out system integrations and repairs. This, too, can result in higher costs. Gaining an in-depth understanding of the breadth of the system’s capabilities can also be challenging. New technologies have lowered the requirements for specialized knowledge as programs have become more user friendly.
Potential Technical Issues: Environmental elements like dust or related debris, inadequate lighting, or even inconsistent conditions within your facility can negatively impact sensors, reducing inspection accuracy.
Incompatibility with Non-Reflective Product Surfaces: Sensors and cameras may have a difficult time measuring plastic parts or components with opaque or black coloring due to the lack of light reflectivity on their surfaces.
Difficulty Selecting Equipment: There are many brands out there to choose from, which can make it difficult to find the right solution for your unique application. Also, some camera brands will sometimes try to upsell their latest products which can lead to applications that use much more expensive equipment than needed.
Vision Inspection Systems From AMD
For high-quality vision inspection systems, Advanced Manufacturing Development (AMD) has the expertise and resources necessary to design and implement customized systems that maximize quality throughout your production line. We integrate state-of-the-art testing technology in our systems, including precision cameras and sensors that enable comprehensive quality inspections for virtually every process and part.
Our automated testing stations and systems will first identify the presence of each part. Then, in addition to checking for flaws or defective components, you can also use these systems to monitor for proper part orientation, color, and surface finish; confirm proper assembly; and accurately evaluate component form and dimensions. Using these vision solutions, you can measure the amount of glue, lubricants, sealants, and other such substances applied to a part, as well.
Let AMD Create a Vision Inspection System for Your Needs
Looking to implement a high-performance vision inspection system? AMD is here to help. We specialize in high-quality, custom automation solutions, including vision inspection systems that incorporate state-of-the-art technology. To learn more about our offerings and capabilities, contact us today, or begin your next project by requesting a quote.
Advanced Manufacturing Development (AMD) provides turnkey services for your global rollouts by standardizing vision inspection systems, so you can guarantee ship dates and comply with all international and domestic guidelines. We create repeatable solutions, which are tested thoroughly before they roll out nationwide or worldwide. We take standard systems and select the right camera, mechanisms, lighting, and other hardware and software for the application.
Our vision inspection systems fit your precise setup, enabling you to adhere to all local standards without having to redesign anything. Standardization creates consistency across inspection programs, system controls, mechanical setup, and electrical components.
As vision system specialists, we focus solely on creating solutions that are custom-designed, programmed, and fully automated for use in every system on your plant floor. AMD works directly with you to create a vision inspection system to address your unique needs, deliver the best achievable pass/fail rates, and reduce liability.
When you partner with AMD to integrate your machine vision systems, you gain access to the following benefits:
High degree of precision (inspection and verification)
High speed/high production rate applications
Improved repeatability (GR&R)
Stringent pass/fail rates
Quality, purpose-built systems that are long-lasting, low maintenance, and reliable
Detailed and documented system designs that can be repeated to multiple plant locations and/or lines
4 Things to Look for in a Vision Integrator
When looking for a machine vision integrator, there are four important things to look for:
1. Excellent Client Relationships
Ask for references from other clients and contact them about their experiences on past machine vision projects. A good machine vision integrator will be responsive and collaborative with the client to best meet their needs.
2. Feasibility Lab
A high-quality machine vision integrator will have a feasibility lab to thoroughly develop the scope and specifications of a machine vision job. This lab will have the ability to create a miniature version of the proposed system and will be able to test and retest it to reach the optimal design.
3. Front-End Engineering
The goal of front-end engineering is to completely understand the client’s expectations of their vision inspection technology. This includes any pass/fail rate success criteria and custom specifications.
4. Project Management and Technical Expertise
Ask the references about the integrator’s project management and technical expertise. It’s also important to make sure the integrator can provide examples of past projects and discuss in detail about the challenges and progressive steps of your machine vision system project. Adept project managers and technical experts are necessary for successful outcomes, speed, and cost management.
Machine Vision Integrator Applications
Machine vision integrator applications include:
Robot guidance. Vision-based solutions work to guide the movements and positioning of robotic systems. This cuts the need for hand tooling and labor. For example, a robot using a vision system can correctly pick parts from a conveyor belt, even if the parts are not in a fixed position. They can also load parts onto worn or deformed pallets without the risk of crashes and spills.
Defect detection. Vision systems can detect defects, such as cracks, porosity, voids, etc., on the surface of parts to improve quality and reduce scrap.
Assembly verification. These systems can verify the presence of objects within a given area. This ensures that all pre-programmed objects are in their precise spots within a given location for both manual and machine assembled components.
Part identification. Part identification ensures that correct parts are present and tracks the item throughout the assembly process. Examples include Datamatrix, 1D Barcode, Optical Character Recognition (OCR), and more. This provides full-scale traceability throughout the manufacturing/assembly process and reduces nonconformities.
Contact Advanced Manufacturing Development (AMD)
Partnering with the right machine vision distributor can provide added value and peace of mind when it comes to meeting your application and business objectives. At AMD, we are committed to applying our technical knowledge and project management skills to design the vision systems based on your specifications and requirements. To learn more, contact us today.
Numerous industries rely on vision measuring systems as part of quality assurance processes. Vision measuring systems use a camera, lighting source, and intelligent detection software to closely measure the work performed in various processes to ensure it was completed within acceptable parameters. For example, the automotive sector might use a vision measuring system to measure the sewn seams found in automobile upholstery for seam quality and color.
As a world leader in metrology, Advanced Manufacturing Development (AMD) can provide you with a vision measuring system to help you ensure the products you manufacture are of the highest quality. Each of our system’s components are designed using the latest computer-aided design (CAD) techniques, ensuring the best performance from your new system. We use only the best materials and components available to facilitate flawless performance and long service life from the equipment we produce.
We equip each system with powerful, built-in vision probes for a crystal clear view and precise measurement each time. Our design incorporates contact probes to further extend the equipment’s measuring capabilities. AMD’s dedicated analysis software efficiently measures and interprets results, so your plant can keep pace without sacrificing impeccable quality.
What Can Vision Measuring Systems Accomplish?
Vision measuring machines — also known as video measuring machines or optical measurement systems —help you identify potential defects faster and with better accuracy. These measuring systems help manufacturers across numerous industries to meet measurement goals and verify the quality of their processes. Machines are available with different optical zoom capabilities and sensor options for measuring two-dimensional and three-dimensional parts.
In the automotive industry, vision measuring systems verify that complicated assemblies are aligned properly before they leave the plant. By taking detailed measurement and analyzing the results, these machines allow you to measure every detail and certify that the component meets internal and industry standards. Common applications include the automated assembly of electric vehicle motors, as well as the seats, windows, and many other components of the vehicle.
Vision Measuring Systems Solutions
Manufacturing relies heavily on complex miniature components that require careful measurement. An increasing demand for accuracy in production will require manufacturers to invest in technology that reduces operator error and lowers defect rates. As technology advances, expect increasingly intelligent optical measuring systems to emerge that feature minimal measurement programming, high-resolution field-of-view measuring, and increasingly intelligent automated capabilities.
If you are looking to invest in a vision measuring system for your facility, evaluate your options based on the technology, knowledge, and expertise available to you from the manufacturer. Vision measuring systems are highly customizable to the needs of numerous industries and applications, so make sure you find a machine that is tailored to the needs of your team and your operation.
Vision systems can do much more sophisticated measurements like checking all the components are present, that there is no pollution in a process, parts are assembled in the right order, etc. In these types of systems, you do not get an actual measure of a part, but you do get information that lets you determine if a part is good or bad.
AMD Vision Measuring Systems
At AMD, our systems and personnel are up to date with the latest functions and trends in metrology solutions and technology. We ensure your new vision measuring system continues to operate accurately and efficiently with regular software updates. During our sales process, our team is happy to provide you with benchmarks and sample reports so that you can evaluate the track record of our systems prior to purchasing. We want you to have complete peace of mind that our machines and team will provide you with uncompromising quality and support. Check out our other test systems we manufacture.
AMD has been creating cutting-edge manufacturing solutions since 1996. We have the products and experience to help your facility meet the demands of the modern world. Contact our team to learn more about our vision measuring systems.