Inspection Solutions
We define our inspection solutions as traditional (or rules-based) or artificial intelligence (AI). We have the expertise to help you identify the right type of solution for your application. A great machine vision solution can be a blend of both automated approaches, and even an enhancement of the existing human inspection.
| Human Inspection | Traditional Inspection | AI Inspection | |
|---|---|---|---|
| TYPE | Learn by example | Rules-based programming | Learn by example with the speed, accuracy, and repeatability of a rules-based system |
| PROS |
+Able to handle large variation and complexity +Able to discern between acceptable variation and defects |
+Speed +Accuracy +Repeatability +Small details +Better for measurement applications |
+Accuracy +Repeatability +Able to handle large variation and complexity +Able to discern between acceptable variation and defects +Small details |
| CONS |
-Low accuracy and repeatability -Slow -Small details -More costly, especially with multiple shifts |
-Not able to efficiently handle large variation and complexity -Better for simpler inspections |
-Not appropriate for measurement applications -Training sample requirements |
Benefits of Vision Inspection to Manufacturers
Reduce direct labour, sorting and scrap costs
Improve human safety in dangerous, dirty, and dull environments
Fulfill contractual inspection requirements
Enhance human inspectors (add to visual inspection)
Perform inspections beyond human capabilities
Integrated data solutions for traceability and process optimization with Proximity Smart Support
What Type of Inspection Solution is Right for You?
Defect Detection
Enhance product excellence and consumer trust with automated defect detection to swiftly identify imperfections in your process, delivering top-tier quality assurance.
Assembly Verification
Secure flawless product assembly with automated verification of your critical features, ensuring every component meets your high-quality standards.
Option Classification
Customize with confidence with automated option classification, ensuring you can cater to your customer's preferences and deliver excellent and traceable quality.
Optical Character Recognition (OCR)
Bolster confidence with fast, reliable optical character recognition (OCR), ensuring accurate part tracking through your process for system traceability, or guaranteed readability of critical information.
Revolutionize Your Inspection Process with AI-Powered Precision
Augmenting your quality inspection process with AI can be a game changer. But it is not always the right approach for the application. We understand how to unlock its full production potential for manufacturers, and we have developed the supporting infrastructure to sustain every new level of quality.
Introducing 3D-AI Weld Inspection
In modern manufacturing, ensuring weld integrity is critical to maintaining product quality, safety, and compliance. The 3D-AI Weld Inspection solution from TrueLight automates the evaluation of welds with unmatched precision and consistency. Combining state-of-the-art 3D imaging technology with the power of artificial intelligence, it empowers manufacturers to elevate their quality assurance processes.
3D-AI Weld Inspection is designed to be integrated into new or existing production lines, minimizing disruption while commissioning the solution to your specifications. The solution’s modular architecture allows for customization to meet specific operational requirements, whether inspecting complex weld geometries or adapting to high-speed production environments.
With over 25 years of integration experience that has been honed in demanding sectors such as the automotive manufacturing industry, we understand what it takes to design, ramp-up, and support an automated inspection solution that is critical to quality and production.
Case Studies
2D Measurement of EV Battery Cooling Plates
Our customer required an automated solution capable of inspecting the dimensional accuracy on fitting placement of battery cooling plates designed for electric vehicles (EVs). There were three (3) different part variants.
The piece of equipment would be manually tended (loaded/unloaded) by operators and the total cycle time required was 20 seconds, regardless of part variant. Manual changeover between part variants with required time of less than 10 minutes.
TrueLight designed a gauge machine to be placed beside a previously integrated BOS L-MS laser welding cell at the customer facility. This automated quality inspection equipment features a vision system, and an operator load station.
The vision system was comprised of 10 Basler 5 MP GigE Cameras, 3 Keyence Barcode Scanners (1 for each part variant), a Keyence High-Speed Optical Micrometer, and dome lights to visually indicate pass and fail of each scanned part.
The automated solution has been successfully integrated into the production line with a 20-second part-to-part cycle time, and is achieving quality, and technical availability requirements for our customer.
Additionally, by having integrated several gauge machines in the past, TrueLight has streamlined the integration costs of these quality inspection systems and was able to pass these savings on to the end customer.
2D Cobot Vision Inspection of Assembled Seats
The project involved the final assembly of automotive seats for a Tier 1 manufacturer, where quality control and assurance were critical in ensuring the integrity of the manual assembly process. The manufacturer produced 27 part variants, including both front and rear seat configurations, all of which needed to be inspected within a strict cycle time of 50 seconds.
To meet the customer's requirements, the system needed to support automatic changeover between the variants and operate without the need for physical guarding, such as fences.
The solution implemented involved an in-line 2D image capture and processing system. This was achieved using a 2-megapixel Cognex camera paired with a CR-35 FANUC robot.
The system performed over 190 unique inspections, including checks for part presence, various options, and correct orientation. The use of this collaborative robot (cobot) ensured that the system could handle the required inspections with precision and reliability while working alongside human operators without the need for physical barriers.
The project delivered a turnkey solution that included a third-party Pre-Start Health and Safety Review (PSHSR) conducted in Ontario, Canada, ensuring compliance with local regulations.
This implementation marked the customer's first cobot in production, streamlining their inspection process and meeting the stringent quality control demands of their final assembly operations.
Precision Measurement for 5-Axis CNC Laser Cut Metal Tubes
Our customer required 100% 'in-line' inspection of 10 laser cut features (position, diameter, and shape) on octagonal tubes with tight tolerances.
TrueLight tested and selected a high resolution Cognex camera with specialty optics and lighting for the application. The camera was mounted on a high precision single-axis motion system to allow for the inspection of multiple features along the length of the part. To allow for features to be inspected on all eight sides of the octagonal part, the part was fixtured on a rotary axis.
As part of a turnkey system integration, a material handling robot loaded and unloaded the inspection station to ensure every part that came out of the BOS L-MS laser cell was immediately validated as 'good' before being passed downstream. The system automatically rejected all 'bad' parts.
The inspection system was successfully integrated into this production line with a 20-second part-to-part cycle time. The system achieved a Gage R’n’R result of less than 10% and it demonstrated a static repeatability of 0.006mm.
Integration Capabilities
|
2D iRVision 2D |
|
3D 3DL 3DA 3DV |
|
2D In-Sight 2000 In-Sight 2800 In-Sight 7000 In-Sight 3800 D900 VisionPro/ViDi |
|
3D L4000 L38 |
|
2D IV3/IV4 VS CV-X/XG-X TM |
|
3D IX LJ-V LJ-X XT |
|
3D Gocator Series GoPxL FactorySmart AI |
STEP INTO THE FUTURE OF QUALITY INSPECTION
Contact us today. Let us help you redefine what is possible with automated inspection.