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Industrial image processing

Industrial image processing, as a non-contact or non-destructive inspection, is used both for the visual inspection/testing of components/assemblies (according to pre-defined features such as surface texture/condition, colour, contour, shape etc.) as well as for monitoring production processes (automated control and inspection of individual production stages). In other words, ideal for assuring, monitoring, and documenting production and product quality alike.

With skillful robotics (Robotic Process Automation for Efficiency Optimization) or other handling technologies/systems, image processing methods may furthermore be deployed in test process areas in which humans, in a conventional setting, would otherwise be exposed to unnecessary risks and dangers.

Moreover, avoidable errors in the production process are often caused by inadequate or less than 100% quality control measures. During random or visual inspections conducted by humans, manufacturing defects are often not detected. This is how defective components get into the production process. Errors and defects in the further manufacturing process (expensive rejects), customer dissatisfaction/complaints, and returns are inevitable. With consistent automatic inspections via image processing systems, all these quality assurance issues will soon be a thing of the past.

As a key element, the vision control system is deeply integrated and embedded in the customer-specific plants or custom machines designed and produced by esmo automation: for quality inspection/control as well as a control instrument or monitoring tool for various inspection aspects, methods, and procedures (object identification, presence detection, completeness check, position/orientation check, check for damage etc.). Of course, the overall process, including upstream and downstream sequences, i.e. any handling processes prior to and after visual inspection, will be taken into account as well. Always in our focus: the best possible and optimal solution for your tasks and requirements.

As system integration specialists in the field of automation, we combine the most modern possibilities of industrial camera and lighting technology with the potentials of automation technology. With this technological symbiosis we achieve an optimum of dynamic, high-precision processes for a premium-quality, industrial manufacture of your products.

Applications of image processing

With camera and image processing systems for the optical inspection and recognition of surfaces and geometries, most diverse inspections may be performed:

  • presence detection
  • completeness checks
  • object identification
  • position/orientation checks
  • checks for damage
  • part measurement
  • component analysis, component diagnostics
  • 2D/3D surface testing/surface inspection
  • geometrical testing
  • detecting/reading/scanning and checking barcodes, DataMatrix codes, QR codes etc.
  • and many more

Automated optical inspection (AOI) for visual quality control

Automated optical inspection – in short, AOI – is used whenever measuring and inspection processes with different basic prerequisites (e.g. in quality assurance, in measuring/test technology) have to be automated. AOI systems are employed, among other things, in order to –

  • detect 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.
  • identify volumes and shapes: The 3D inspection feature measures volumes and shapes.
  • inspect surfaces: Components will be checked for scratches, cracks and tears, paint damage, colours, inclusions as well as relief lettering/inscriptions – application of this inspection feature also possible with reel material/tape stock as well as with curved and reflective surfaces.
  • check completeness: Product features/properties will be counted, placement/loading will be checked, product carriers will be inspected.
  • read codes: Read and validate various different codes.

With optical inspection systems, also referred to as machine vision (systems), defects may be identified at an early stage, thus significantly reducing the number of rejects/waste of further processed/refined goods – the result: maximum quality at minimum effort PLUS increased output and profit.

Fully integrated, customized AOI systems

We configure an AOI system or vision system for your plant or custom machine according to your individual quality control requirements and at the most favourable price/performance ratio. To this end, we co-operate with renowned suppliers – such as Keyence, Cognex etc. – in order to consistently and sustainably ensure optimum cycle times, precision, and cost efficiency. Even with very complex systems or challenging component handling demands, we always find a solution, individually tailored to your requirements, that will convince you.

optimized cycle times with fully integrated industrial camera systems

By directly interlinking the employed machine vision systems with the actuators of the plants and custom machines, we create highly precise processes even at alternating conditions, thus generating optimum cycle times at consistent, premium quality levels. We offer you a maximum of configuration flexibility, and are also completely flexible in our manufacturer/brand choice (camera technology, lighting, handling components etc.).

targeted plant control with professional monitoring

The long-term storage and evaluation of test results generated by optical inspection systems allow for the targeted control of upstream processes, thus ensuring optimum plant utilization at minimum reject rates.

With the employment of data servers in the plants, machine conditions and incidents may be documented, and a close plant monitoring and controlling may be guaranteed – consistently following the approach and the standards of Industry 4.0.

24/7 inspection for manual and production-related error prevention

The image processing systems for automated visual or optical inspections, integrated by esmo automation, detect all standard deviations as well as all signs of material wear – without any contact (non-contact) and with utmost precision, at a reliably consistent process speed, around the clock.

With our automated, optical quality control systems, sensitive materials can be protected against damage, test materials against contamination – furthermore, manual errors and failures, caused by human deficiency, may be sustainably prevented or reliably excluded.


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