Automating quality inspection in real-time for a top Korean manufacturer of sealing and inspection systems
About the client
The client, based in Korea, provides complete solutions that span technical review, manufacturing, delivery, local installation, and tryout for sealant equipment, and visual inspection systems. They also have global footprints across US, Japan, and some parts of Europe.
Key Challenges and customer's expectations
The client’s primary expectation was a vision-based quality inspection system to automatically capture and detect product defects in real-time on the edge. But they were not in favor of using expensive machine vision cameras. They also wanted to improve workforce safety by automating quality inspection in harsh working conditions.
While e-con Systems has significant experience in creating cost-efficient, automated quality inspection solutions, there were industry-related challenges that stood in the way.
Some of the challenges included:
Size of surface: The material surfaces of products for which defects had to be detected were considerably large-sized.
Quality assurance: Uncompromisingly high level of quality, which meant even detecting minor defects on the surface
Movement during detection: The cameras had to be placed on a moving robotic arm for a quick inspection of products. Images had to be captured with close to zero motion blur
Selection of the camera module
Multiple cameras were required considering the material's size and shape, and the movement of the robotic arm on which each camera had to be placed. Hence, our camera module selection was based on the ease and effectiveness with which multiple cameras could synchronously capture images.
e-CAM55_CUMI0521_MOD was the perfect match since its large pixel size could capture superior-quality images with low exposure time. It came equipped with ON Semiconductor's AR0521, a 1/2.5" image sensor with 2.2μm pixel size, and a powerful onboard image signal processor for exact color reproduction.
Powered by real-time edge processing algorithms, this off-the-shelf module enabled all the images from multiple cameras to be captured in the exact same instance and processed accordingly.
How e-con Systems™ delivered a hassle-free solution
We believe in going the extra mile during the first step. It’s why we practically validated the e-CAM55_CUMI0521_MOD module before working on the end solution.
Using our own USB camera See3CAM_CU55, we captured images of relevant material surfaces and handed them to the client for evaluation, along with the algorithm. Upon validation, we started custom-designing a synchronous setup of six e-CAM55_CUMI0521_MOD modules. Connected to the NVIDIA Jetson TX2 board over a MIPI interface, its algorithm could instantly process high-quality images in memory.
To support the long-distance cabling, we used GMSL coaxial cables between the host and cameras. Since e-con Systems was one of the earliest adopters of GMSL technology, we knew what it took to carry high-speed video, bidirectional control data, and power over a single coaxial cable. It helped us achieve synchronization and low latency on the image pipeline from the multi-camera setup for the client.
The client could navigate past challenges like harsh environments, unpredictable lighting conditions, and motion blur by ensuring:
- Support for various image quality controls
- Excellent image quality in challenging lighting conditions
- Low exposure time to eliminate any chance of motion blur
- Automation of the manufacturing unit – leading to lower risks, higher cost savings, and smoother operations
- Improved staff safety by eliminating the need to manually conduct quality inspection
- Better working hours and reduction of repetitive manual tasks – leading to increased workforce efficiency
- Elimination of costly human errors with better inspection accuracy
Talk to us
Interested in knowing more about how you can reimagine the way you inspect product
quality in tough environments?
Connect with our product manager, who worked on this vision-based solution, and get started!
About e-con Systems™
e-con Systems™ is a leading OEM camera manufacturer with 17+ years of experience and expertise in embedded vision. It focuses on delivering vision and camera solutions to industries such as retail, medical and industrial. The company’s wide portfolio of products includes MIPI camera modules, GMSL cameras, USB 3.1 Gen 1 cameras, stereo cameras etc.
e-con Systems™ strives to become a global leader in the embedded vision space through continuous innovation, and helping its customers accelerate product development and reduce time to market. It has built over 250+ product solutions and shipped over millions of cameras around the globe. What sets the company apart is its deep expertise in building customized product designs while ensuring rapid prototyping and custom modifications in hardware as well as software.
Disclaimer and copyright statement
This content is owned by e-con Systems and not meant for public distribution. Any reuse of this content can be done only with the prior written permission from e-con Systems. e-con Systems also holds the right to modify any information stated in the document.