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.

Training, Validation, Deployment, Support banner

AI vs Traditional vs Human Inspection Chart

Introducing 3D-AI Weld Inspection

In modern manufacturing, ensuring weld integrity is critical to quality, safety, and compliance. TrueLight’s 3D-AI Weld Inspection automates weld evaluation using high-resolution 3D imaging and AI-driven analysis to deliver fast, repeatable results.

Designed for new or existing production lines, the solution supports flexible part families and weld geometries with a modular architecture that minimizes disruption at commissioning. From validation to long-term support, TrueLight helps you build a reliable inspection process that scales with production.

Learn More About Our 3D-AI Weld Inspection Solution

Add to Your Inspection Toolkit: Quality & Gauge Solutions

TrueLight’s Quality & Gauge Solutions combine precision vision inspection, robotics, and real-time analytics to verify critical features at the point of production. Whether you’re checking geometry, presence/absence, or functional gauge conditions, these stations are built for repeatability and speed.

Our modular approach integrates smoothly with existing processes, enabling traceability and consistent performance over time. Backed by Proximity Smart Support™, you gain the visibility and responsiveness needed to keep inspection running and production moving.

Learn More About Our Quality & Gauge Solutions

Case Studies

2D Measurement of EV Battery Cooling Plates

Requirements

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.

Solution

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.

Results

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

Requirements

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.

Solution

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.

Results

Precision Measurement for 5-Axis CNC Laser Cut Metal Tubes

Requirements

Solution

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.

Results

Integration Capabilities

FANUC
2D iRVision 2D
3D 3DL 3DA 3DV

Cognex
2D In-Sight 2000 In-Sight 2800 In-Sight 7000 In-Sight 3800 In-Sight 8900 D900 VisionPro/ViDi
3D L4000 L38

Keyence
2D IV3/IV4 VS CV-X/XG-X TM
3D IX LJ-V LJ-X XT

LMI
3D Gocator Series GoPxL FactorySmart AI

Inspection Solutions

Benefits of Vision Inspection to Manufacturers

What Type of Inspection Solution is Right for You?

Defect Detection

Assembly Verification

Option Classification

Optical Character Recognition (OCR)

Revolutionize Your Inspection Process with AI-Powered Precision

Introducing 3D-AI Weld Inspection

Add to Your Inspection Toolkit: Quality & Gauge Solutions

Case Studies

2D Measurement of EV Battery Cooling Plates

Requirements

Solution

Results

2D Cobot Vision Inspection of Assembled Seats

Requirements

Solution

Results

Precision Measurement for 5-Axis CNC Laser Cut Metal Tubes

Requirements

Solution

Results

Integration Capabilities

STEP INTO THE FUTURE OF QUALITY INSPECTION