Defect detection determines the success or failure of the automated visual inspection station

The VIS-I solution is a complete, integrated inspection station that utilizes Radiant Vision Systems' ProMetric® imaging luminance meter or colorimeter, brightfield illumination and programmable inspection software to identify complex component assembly and low contrast Subtle defects on the surface of the part. The system can be easily added to the production line for real-time inspections, enabling greater precision and repeatability than manual inspectors and traditional machine vision systems, and taking up only the space required by a manual inspector on the production line. The VIS-I is able to track the parts being inspected by serial number while recording defects, defect types and defect trend data. The system uses a wide range of inspection tools included in Radiant's industry-leading TrueTestTM automated vision inspection software to perform a series of machine vision inspections (including positioning, counting, measuring, OCR, etc.) simultaneously or sequentially.

The VIS-I system is suitable for a wide range of inspection applications, including sub-assembly and total assembly verification of highly complex electromechanical components, surface appearance inspection of fine flaws on high-value parts, and identification of surface or internal foreign objects. Detection, etc.

Replicate the detection and judgment ability of the human eye

In some manufacturing environments, traditional machine vision functions are no longer sufficient because they require not only the human detector's superior ability to sense defects, but also the high efficiency of the automation system. The VIS-I system can Provide the ideal solution.

Manual inspectors can detect subtle defects by their ability to detect and determine if the type of defect, its population and extent are within acceptable tolerances. However, after several hours of continuous detection of complex parts and subtle changes, the human inspectors feel fatigue both physically and mentally, resulting in a decrease in their detection accuracy. Of course, scheduling another inspector to perform repetitive testing at the same time may be a solution, but it can be costly. Just calculate the average flow rate of the manual inspector within two to four months, we will find that in order to support this mode of testing operations, companies need to invest a lot of time and cost in personnel recruitment and training, which will Further complicate matters. The VIS-I automated vision inspection solution delivers absolute accuracy with a single inspection with continuous performance and reliability. The VIS-I is calibrated to simulate the sensitivity of human vision to contrast, which enables it to simultaneously identify diverse fuzzy features without the need for repeated detection. At the same time, the system has advanced logic capabilities that can be used to determine pass/fail with specific defect tolerances while providing excellent objectivity and repeatability to manual inspectors.

Unparalleled camera resolution and dynamic range

The performance of a machine vision inspection system depends on the acquisition of high quality images, ensuring that the system can “see” more details of the parts and defects and use meaningful evaluation to define these details. Standard machine vision camera sensors typically have resolutions from 1 million to 5 million pixels. The VIS-I inspection system takes full advantage of the superior resolution (up to 29 million pixels) and dynamic range (up to 73.4 dB) of the ReMed optical system ProMetric imaging luminance meter and colorimeter for unparalleled image clarity .

The ProMetric camera's CCD sensor has a high dynamic range, which allows the system to detect hair-like subtle changes in the surface of the part due to light reflections (eg, shadows indicate scratches and spectral reflections indicate metal parts). This feature, combined with the camera's high resolution, allows the VIS-I to capture images with extreme precision and classify defects while maintaining high image processing speed and low image noise (ProMetric camera CCD sensor Interlaced cooling reduces noise). The VIS-I can even detect defects that may be overlooked by manual inspectors, including slight scratches on the glass, gaps of less than 1 mm between different keys on the keyboard, and the presence of tiny black screws in the holes on the black parts. / missing. VIS-I provides production-grade inspection solutions with highly accurate tolerances, not only with the objectivity, durability and repeatability of machine vision systems, but also for visual inspection capabilities that are equivalent to or even beyond human perception. This combination addresses the need for high-value and high-risk product manufacturing for operational efficiency and absolute product quality.

Image analysis based on luminance meter

Because the machine vision software of the VIS-I system is based on Radiant Vision Systems' industry-leading optical measurement software, VIS-I can detect complex details of components in the same way as light characterization. The user can make full use of a software tool for detecting (in the illuminating component) the minimum sensible difference in visible light uniformity to detect abnormal contrast changes (on non-illuminating components). This feature allows VIS-I to identify unknown defects (unpredictable features and shapes) at unknown locations (unprogrammed points of interest) as well as manual inspectors. But unlike manual inspectors, the VIS-I system accurately detects specific types of defects and classifies them, assigning specific values ​​to each defect, and targeting the severity, extent, or Diffuse, quantify the exact acceptable tolerance range. The VIS-I can be operated independently, without the need for manual inspectors, and can be used to expand or perform manual inspection verification in applications that require manual inspectors.

The system can be directly installed on the production line

The VIS-I is designed to be integrated directly into the production line and with an adjustable frame that can accommodate conveyor belts from 525 mm to 950 mm. The total operating area is 1860 mm (H) x 800 mm (W) x 700 mm (D), taking up only the space required by a manual inspector on the production line. The integrated ProMetric camera and machine vision lighting are all packaged in the VIS-I frame, which not only prevents interference with other devices, but also eliminates the effects of ambient light, allowing the VIS-I to capture the highest contrast images and ensure that the parts are Reliable detection. Since the parts on the production line are always in motion, the integrated sensor in the VIS-I system (users can also choose to integrate the reader) can provide the “part-to-place” trigger function. When the part enters the field of view, it prompts the camera and The illuminator collects an image of the part. This method supports line speeds of up to 122 mm (0.4 ft) per second with index times between parts as short as 7 seconds.

Specially designed to meet different inspection needs

All successful machine vision installations require a comprehensive understanding of each inspection requirement. Radiant's team of application engineers work closely with customers to determine the VIS-I specifications that are best for them and to tune the system to precisely meet the various defined parameters. Each VIS-I system is unique in terms of components and design, with system height, integrated lighting, illuminator geometry and cameras that can be adjusted or replaced as needed to meet various system sizes, part surfaces and shapes, and Imaging resolution requirements. Manufacturers can choose ProMetric Y Series Imaging Luminance Meter (resolution options: 2 million, 16 million and 29 million pixels) for monochrome imaging, or ProMetric I Series Imaging Colorimeter (resolution options: 2 million, 8 million) , 16 million and 29 million pixels) solve color imaging applications that require color recognition, matching and verification. All cameras can be used with ProMetric or TrueTest software platforms to access Radiant's complete library of image analysis and inspection tools.

Complete machine vision tool library with extensively validated test sequencing software

Based on Radiant's field-proven TrueTestTM software, VIS-I system software has a comprehensive library of inspection tools that perform a variety of basic machine vision functions to validate and measure electromechanical components. These tools ensure the manufacturing accuracy of the device and its components (tools include positioning, measurement, presence/absence, edge detection, measurement, etc.).

By leveraging high resolution, high dynamic range, and the evaluation of the minimum perceived difference (JND) based on a luminance meter, VIS-I is also capable of performing surface inspections to identify anomalies such as scratches, indentations, spots and foreign objects. VIS-I uses a luminance meter based gradient and contrast evaluation to locate and identify contrast anomalies in the entire image, enabling detection of subtle defects that traditional machine vision systems may overlook, preventing the assembled equipment from being shipped from the factory. Potential failure.

Figure 1. The VIS-I software is capable of performing multiple inspections simultaneously, identifying various assemblies and surface defects with a single image, and passing/fail analysis based on defined tolerances.

Figure 2. VIS-I is able to detect a variety of subtle defects, such as wire laying errors. It is well known that during the use of the product, if the wire is often deviated from the plastic rail, it may cause potential failure of the product.

Main features and highlights of the product:

· Evaluate product quality with greater precision and consistency than scheduling multiple manual inspectors to perform repetitive testing

· Track defect trends and classify defects by type, test, or location on the product to determine extent and severity

· Equivalent to human perception in terms of low contrast defects and component identification

· Automated online inspection with only the space required by a manual inspector on the production line

· All-weather (24 hours / 7 days) operation and ensure high repeatability

· Even a large product to be inspected, only a single image can be acquired for measurement

· Analysis software can set complex pass/fail criteria for each specific inspection application

typical application:

The VIS-I system combines unparalleled high-resolution imaging with the most powerful machine vision software tool library to detect defects that traditional machine vision cameras can often overlook. The VIS-I system can be installed directly on the production line, helping users to ensure continuous production while solving various applications, including:

• Subassembly verification: presence, location, and path of wires/cables, fasteners, connectors, screws, and internal components

• Total assembly verification: gaps, steps, bonding, aperture alignment, label/identification quality, and posting

• Appearance quality control: scratches, indentations, fingerprints, dust, bubbles, point defects

• Product tracking, reporting and manufacturing records for process control