"The IDS cameras integrated into the test cells capture high-resolution images of the surface of aluminum components from German OEMs, in this case an electric motor," says Uwe Siegwart, Managing Director at Vivaldi, explaining the camera's task. The captured images are pre-processed to optimize factors such as exposure, white balance and color correction. The AI recognizes various surface defects such as scratches, pores or dirt. "There are strict requirements at the plant in the Czech Republic. According to the defect catalogue, defects from 0.2 millimeters must be reliably detected. The test time per component must not exceed 36 seconds," says Uwe Siegwart, explaining the stringent guidelines. Up to 2,400 electric motor housings per day are tested 100 per cent automatically with the successfully implemented system.

"The decisive factor was that the autofocus camera can capture several surfaces at different distances from the camera." says Eike Humpert from Vivaldi's Business Development department. This simplifies the testing process enormously and ensures greater efficiency and flexibility. This is a crucial factor when, for example, different component variants need to be tested. With the macro attachment lens, the minimum object distance of the camera can also be shortened very easily.
"The BSI pixel technology enables the sensor to deliver consistently precise and reliable results, even in changing light conditions," explains Jürgen Hejna, Product Owner 2D cameras at IDS. It is not only the excellent low-light performance and minimal pixel noise that make the sensor particularly suitable for this application. "The 24x digital zoom, combined with auto white balance and precise color correction, contributes significantly to the success of this demanding test procedure," emphasizes Jürgen Hejna.

The simultaneous image processing task is complex and the challenges are diverse. Aluminum parts often have very shiny surfaces that reflect light and therefore have a strong influence on images. These reflections make it difficult to reliably recognize defects such as scratches, cold runs, chatter marks or surface irregularities, as they are often obscured or distorted by light reflections. This, along with other material and environmental variations, means AI-based image processing must therefore be able to distinguish precisely between the normal material structure and actual raw areas in surfaces to be processed that are considered defects.
Image processing is carried out via an optimized infrastructure. Up to eight cameras can be connected per USB hub, enabling simultaneous recording of several inspection areas. A maximum of two of these USB hubs are connected to a self-developed 'cam controller', which bundles and processes the image signals. Several cam controllers are networked with the edge server. This server not only calculates the AI-supported analyses, but also communicates directly with the system controller, which coordinates the triggering of the cameras and ensures synchronized recording.
"Image processing is a central component for traceability, which is the actual technological centerpiece of the solution, and IDS is the ideal partner for this point”, underlines Uwe Siegwart. "Digitized quality data acquisition in real time and linking with other production parameters not only increases efficiency, but also significantly reduces rejects and rework. Errors are minimized, costs are reduced and production processes are optimized."
The system has already paid off in the Czech Republic: The number of complaints per year has been reduced by two thirds and the number of unrecognized surface defects has even been reduced to zero.

The market for digital quality control is developing rapidly, particularly due to more favorable camera technology, for example with regard to higher resolutions. Optimized image processing processes and tools also make it possible for real-time analyses to be carried out by end users," states Eike Humpert. "Improved resolution, more compact design and price-optimized cameras are in demand." The portfolio of the industrial camera manufacturer IDS is designed to meet this demand with state-of-the-art technology.

Model used: U3-36LOXC
Camera family: uEye XC

VIVALDI Digital Solutions GmbH develops state-of-the-art solutions for AI-supported quality control based on the latest computer vision and machine learning technologies. The Vivaldi platform ensures that every component fulfils the highest quality and safety standards, guarantees incorruptible precision and high process reliability in surface visual inspection and raises manufacturing processes to a new level.

 


About IDS Imaging Development Systems GmbH
IDS Imaging Development Systems GmbH is a leading manufacturer of industrial cameras and pioneer in industrial image processing. The owner-managed company develops modular concepts of powerful and versatile USB, GigE and 3D camera as well as models with Artificial Intelligence (AI). The almost unlimited range of applications covers multiple non-industrial and industrial sectors of equipment, plant and mechanical engineering. The AI image processing platform IDS NXT is extremely versatile and opens up new areas of application where classic rule-based image processing reaches its limits. With visionpier, IDS operates an online marketplace that brings together suppliers of ready-made image processing solutions and interested end customers in a targeted manner.
Since its foundation in 1997 as a two-man company, IDS has developed into an independent, ISO and environmentally certified family business with around 350 employees. The headquarters in Obersulm, Germany, is both a development and production site. With branches and representative offices in the USA, Japan, South Korea, the UK, France and the Netherlands, the technology company is also globally represented.