Vision Inspection Systems
Machine Vision systems are low-cost, high-performance online inspection devices that are used to automatically measure parts, verify the correct assembly applications, form verifying print quality, location, and position to deciphering 1-D and 2-D barcodes.
Machine Vision systems help to reduce the human error element on the factory floor. They increase efficiency by providing real time production data for SPC package to provide trending and warn/fail conditions. In order to have 100 percent accurate inspection, it is critical that the installation have proper lighting, lenses, and professional programming.
Machine vision system inspection consists of narrowly defined tasks such as counting objects on a conveyor, reading serial numbers, and searching for surface defects. Manufacturers often prefer machine vision systems for visual inspections that require high speed, high magnification, around-the-clock operation, and/or repeatability of measurements.
Machine vision systems inspect silicon wafers, processor chips, and sub-components such as resistors and capacitors at high speeds with precision and accuracy.
Our Company has dedicated itself to vision by making a long-term commitment to obtaining these results. With a Machine Systems from Firstcall automation, manufacturing has a flexible tool that improves productivity; ensure quality production of a part, increase efficiency, and lower production costs.
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Defect inspection checks for foreign particles, flaws and defects on the surface of parts or products.
Packaging Defects :
wrinkle detection, label placement verification, torn or ripped labels, damaged packaged, misprinted packaging, missing caps, broken seals or poor seals, misshapen packaging, missing packaging, cap defects, tilted caps, cap seating inspection, package tampering, leakage detection.
Part Defects :
broken parts, missing parts, damaged parts, misshapen or malformed products, scratched or dented parts, wrong component detection, part verification, correct tooling verification
Surface Defects :
color detection, texture verification, scratch and dent detection, surface deformities detection, absence/presence verification, surface finish inspection, perforation detection, tear and hole detection
- Monitoring the occurrence of cuts in material.
- Quality check in finished products.
- Checking cuts or damage in o-rings, washers.
- Monitoring fillets in metal ring.
- PCB ICs damage detection.
Measuring in machine vision is used to confirm the dimensional accuracy of components, parts and sub-assemblies automatically, without the need for manual intervention.
- Measuring maximum/minimum dimensions of components, parts or products
- Measuring inner or outer diameters or centre coordinates of circular products
- Measuring the roundness or angle of metal parts
- Dimensional inspection of medical device components and pharmaceutical products
- Measuring label positions, seals and packaging dimensions
- Measuring widths of sheet/film products
- Gauging components on printed circuit boards
- Checking component and sub-assembly positions
- Measuring three dimension of object (Thickness, height, depth, volume).
Presence/absence detection inspection is used to confirm the quantity or the presence/absence of parts or components on a target. There is a considerable variety of presence inspection used in machine vision.
Presence inspection has depended on visual inspection using human operators for many years. However, this involved the risk of missing failures depending on the physical condition or experience of inspectors, the light in the room or the time of day of inspection. Machine vision has been introduced to reduce human errors and improve work efficiency for inspection tasks involving presence verification.
Manual visual inspection causes variations in accuracy due to individual differences among operators and missed quality criteria. 100% quality inspection requires a large amount of time and effort on the part of the manufacturer. To solve these problems, machine vision has been introduced to replace human eyes for recognizing and judging presence targets.
- Verification of clips, screws, springs, components and parts in place
- Counting components in pallets
- Verifying the presence of products in packages
- Monitoring the appearance of labels, marks, print and seals
- Confirming the presence of electronic components on PCBs
- Proving the existence of screws/washers for securing parts
- Verifying the presence of adhesive beads
We provide advanced barcode (1D & 2D) reading capabilities for traceability in a wide variety of industries. We offer rugged, reliable solutions that ensure quality, improve efficiency, and enable accurate inventory management.
- Vision based Barcode reading and verification.
- Package sorting system based on barcodes.
- Lot code and barcode verification system.
- Automatic barcode reading and upload in sap, database.
OCR (Optical Character Recognition) solutions provide robust inspection and verification of complex number, character and language types. This enables the high-speed checking of scribed, stamped, printed or pre-printed text in all languages, fonts, sizes and styles. From packaging label inspection through to laser etched identification of numbers, all character sets can be read robustly and repeatedly regardless of variations in ambient factory conditions and environments.
The template matching wizard within our vision systems allows new datasets and styles to be added easily to enable the training, classification and verification of character sets. By accurately determining the shape, size, consistency and verification of numbers, letters and logos, superior quality can be delivered to your customers.
- Character inspection of part numbers, model numbers.
- Checking expiration dates on food containers.
- Character reading with pre trained data’s.
- Reading and matching Characters with match pattern or barcode.
- Character readability checking for ink printed materials.
Color based inspection helps to identify parts, products and items using color, assess quality from color and isolate features using color. A color-matching tool determines the best matching color from a collection of samples for each region of interest within an image. A color sample can be specified either interactively from an image-with the ability to mask out undesired colors-or using numerical values.
A color sample can be a single color or a distribution of colors (histogram). The color matching method and the interpretation of color differences can be manually adjusted to suit particular application requirements. The color matching tool also can match each image pixel to color samples to segment the image into appropriate elements for further analysis using other tools. The color distance tool reveals the extent of color differences within and between images, while the projection tool enhances color to grayscale image conversion for analysis-again using other tools
Color analysis checks can be used to confirm parts meet strict color band tolerances and to check labels, features, conformal coats, beads and glue.
Overall quality verification of parts, components and sub-assemblies is achieved through color searching, pattern checks and template matching.
Using a machine vision system for color matching enables the segmentation and analysis of products operating in RGB, HSI and LAB color space.
- Color identification.
- Color summarization.
- Sorting based on color in objects
Vision guided robots enable a flexible approach to feeding and product changes, eliminating the need for costly precision fixtures and allowing different parts to be processed without changing tools.
By accurately determining the position of parts to direct robots, find fiducials, align products and provide positional adjustment feedback, our vision systems use reliable template tracking to deliver this flexibility.
- Pick and Place.
- Multiple Quality Checks at a single station