Machine vision or industrial image processing systems serve as visual monitoring tools for the inspection of components, basing on pre-defined features such as surface texture/conditions, colour, contour, shape, and the like. At the same time, production processes may be monitored as well. Individual production stages are thus automatically controlled and inspected. Machine vision or industrial image processing reliably ensures, monitors, and documents the quality of products. And with skillful robotics this technology may also be deployed in test process areas in which humans, in a conventional setting, would be exposed to unnecessary risks and dangers.
esmo automation will provide an entire plant or a custom machine to you in which a vision control system has been integrated and embedded as a key element for quality inspection/control and as a monitoring tool for various aspects like positioning, presence, completeness, impurities etc. In doing so, we also keep an eye on the overall process, i.e. the handling processes prior to and after visual inspection.
For our customers we develop and design individualized systems, tailored to their needs and requirements, as well as associated, appropriate robotics solutions. As system integration specialists we combine the possibilities of camera technology with the potentials of automation technology. With this symbiosis we create highly dynamic and highly precise processes for the premium-quality production of your products, including all relevant documentation and reporting.
We select, configure, and integrate complete and comprehensive machine vision systems. Our wide-ranging service offer includes the selection of appropriate cameras and lenses, system programming as well as supplying adequate lighting and protective housings – single-source, of course.
With the technology of camera systems and machine vision systems, surfaces and geometries may be optically recognized, thus allowing for the application of various testing procedures:
- non-contact testing
- 3D surface testing/surface inspection
- presence detection
- geometrical testing
- testing of DataMatrix codes, QR codes etc.
Machine vision or industrial image processing thus offers the entire spectrum of modern camera technology. This includes among others:
- detecting free protective fields as a safety feature/measure
- measuring positions, e.g. in lattice boxes for the automated gripping/picking from transport containers
- checking the presence of components or component characteristics
- correcting positions, e.g. of the robot gripper
- performing 3D surface inspections by using different lighting, regardless of colour differences/deviations
Visual/optical measuring and testing, in particular quality controls with optical sensors and machine vision systems, are increasingly gaining in importance in most various fields of application. These include, among others, the sectors of automated quality assurance as well as measuring and test technology.
Automated optical inspection – in short, AOI – is used whenever processes with different basic prerequisites have to be automated. An AOI system offers the following features:
- Detecting positions: The 2D and 3D position detection features check the proper and precise positioning of components. The position data will then be transmitted to the robot control in order to enable gripping, i.e. pick and place operations.
- Identifying volumes and shapes: The 3D inspection feature measures volumes and shapes.
- Inspecting surfaces: Components will be checked for scratches, cracks and tears, paint damage, colours, inclusions as well as relief lettering/inscriptions – application of this testing feature also possible with reel material/tape stock as well as with curved and reflective surfaces.
- Checking completeness: Product features/properties will be counted, placement/loading will be checked, product carriers will be inspected.
- Reading codes: Read and validate various different codes with AOI.
Optical inspection systems, also referred to as machine vision (systems), communicate prevalent conditions to the plant, and subsequently trigger corresponding reactions. With their AOI systems, our plants handle processes within minimum cycle times, which otherwise would only be manageable with great effort.
Due to a premature detection of errors and failures the amount of waste of further processed/refined goods may be considerably reduced, thus increasing output and, consequently, profit. Bad/reject parts will automatically be removed, whereas good parts will be sorted and packaged according to their item types in order to prepare and provide them for following process steps. The result is maximum quality at minimum effort.
Fully integrated, customized AOI systems by esmo automation
It will be our task and assignment to create an optimum configuration for your individual quality control requirements in order to equip your plant or custom machine with an AOI system offering you the best possible price/performance ratio. For this purpose we cooperate with highly specialized suppliers to constantly and sustainably ensure optimum cycle times, precision, and cost efficiency.
We integrate various AOI systems, or camera systems, in your custom plant or machine. Here we are extraordinarily flexible and independent of particular manufacturers and/or trademarks, thus allowing us to solely focus on your expectations and requirements. So you will be provided with highly professional camera technology which will be integrated in your plant complex. Even with very complex plants and/or challenging component handling requirements, we – basing on our many years of professional and specialized experience – are always able to create and design solutions convincing our customers.
Fully integrated camera systems offering optimized cycle times
By directly interlinking the employed machine vision systems with the actuators of the custom machines and plants, highly precise processes may be executed, even at alternating conditions. This way, we generate optimum cycle times with our AOI systems, at consistent, premium quality levels. The flexibility of the configuration options represents a great advantage for you, as we are not limited to specific suppliers of camera technology, lighting, or handling components.
Targeted plant control with professional monitoring
The long-term storage and evaluation of test results generated by machine vision systems allow for the targeted control of upstream processes. This ensures optimum plant utilization at minimum reject rates. With the employment of data servers in the respective plants this may be easily realized.
Based on the documentation of plant/machine conditions and incidents, the Industry 4.0 approach is taken up and applied, thus allowing for close plant monitoring and controlling.
24/7 inspection protecting against manual and production-related errors
esmo automation technologies for automated visual or optical inspections base on image recognition and processing systems which conduct automatic checks of positions, presence, completeness, and quality. Our machine vision systems or image processing systems automatically detect any standard deviation as well as any signs of material wear – without any contact and with utmost precision. With optical quality control you will be able to protect your highly sensitive materials against damage and your test substances against contamination.
With the automated quality control systems offered by esmo automation, manual errors and failures, caused by human deficiency, may be sustainably prevented. Any potential hazards due to fatigue, a lack of concentration, and/or distraction of the examiner will be excluded. Furthermore, any erroneous assessments of test situations/conditions at hand, which in the event of emergencies might entail costly consequences, will be eliminated, too.
A further advantage of image-based, automated quality control is the reliably consistent process speed – entirely regardless of time and around the clock.