Artificial vision systems in industrial processes have become an essential part of all industrial plants. At E2M Couth, we are specialised in artificial vision systems applied to different sectors, such as food, beverage, or even chemical products. For this reason, we wanted to prepare this post to tell you about applying these systems within industrial processes.
What are the industrial artificial vision systems that we have at E2M COUTH?
Industrial artificial vision systems are an excellent technological innovation that has managed to transform industrial processes in different sectors. These systems use smart cameras and software to imitate human vision in production and manufacturing settings. What is their purpose? To automate tasks that require the detection, identification, inspection, and measurement of objects or situations in an industrial setting.
These systems have the ability to conduct a wide variety of functions. They can inspect products at high speeds, identify defects invisible to the human eye, and take precise measurements, which are fundamental in processes were margin for error is slight. Industrial artificial vision systems combine hardware and software: the cameras and sensors capture images at the moment of production, while the software processes and analyses these images to make decisions and provide valuable information to human operators.
One of the key advantages of these systems, which we will look at in depth below, is their ability to improve quality and efficiency in production. Since it detects defects and errors during different stages of the manufacturing process, artificial vision is essential to reduce material waste and to guarantee that only products that company with quality standards reach the market. Moreover, these systems are able to operate continuously without tiring or growing fatigued, which makes them perfect for repetitive and demanding tasks.
Why is it important to use artificial vision systems in industrial processes?
Within a factory or industrial processes, there are many companies that draw support from artificial vision systems. This kind of solutions is key to control the different processes carried out on a production line. This need to have vision systems for industries is because they take care of inspecting different products and verifying that all the products that go through the production line are in perfect condition.
This kind of system has mechanisms to analyse and recognise any flaw or undesired element in the products. These systems base their operation on a combination of cameras, sensors, and software that all work together to control, analyse, and detect all anomalies in the production of industrial elements, such as batteries or wiring.
The objective is to check that production takes place correctly. This way, you can make sure that all the parameters you set have been met.
At E2M Couth, we have vision systems for industry that can collect data in real time, so that they can draw up different detailed reports. This is a huge help to see how work is going and to completely improve the entire process. What is more, by using these systems, you meet regulations on safety and quality for your production.
Which solutions do the artificial vision systems for industrial processes that we have at E2M Couth cover?
As mentioned, by applying artificial vision systems to industrial processes, you can obtain different advantages and benefits when using them on a production line. For this reason, we are going to show you some of the uses you can make of these systems at an industrial plant:
- Complete product control: Artificial vision systems in industrial processes fulfil the mission of ensuring complete control over the entire production process. The different actions they carry out while inspecting include analysing labelling, distribution zones, etc. This means that you can control each one of your products when they leave your plant.
- Packaging inspection: In every production process, a key moment is packaging. By applying these systems, you can control packaging at all times to see if there are any problems.
How do artificial vision systems in industrial processes work?
Artificial vision systems in industrial processes conduct different processes, so we are going to explain how they work. The systems begin by capturing images with their cameras or sensors. The images may be colour or black and white, depending on the process’ requirements.
After this, the system analyses and processes the images. At this step, sometimes we can improve the quality of the image to correctly adjust lighting, as well as contrast and other aspects for a clearer, sharper image.
Only in this way will the system be able to pick up on all the characteristics of the images for an in-depth view of the product under analysis. This means identifying shapes, edges, colours, texture, and other visual attributes that help to distinguish important characteristics for inspection or process control.
This way, by using algorithms and image processing techniques, the system is able to analyse all the characteristics extracted from the images to detect all defects. It also measures the dimensions of the products and can verify whether its labelling is correct.
After conducting the different analyses, the time comes for these artificial vision systems in industrial processes to make decisions based on the data they have obtained. In this regard, to make things simpler, the system can differentiate between accepted and rejected products, based on the quality criteria stipulated for the system.
In closing, you should know that these systems tend to be designed to learn and improve with the passage of time. For this reason, with the data collected during inspections, they can adjust the different algorithms and improve precision for following operations. This is how artificial vision systems in industrial processes work.
Discover the key components of industrial artificial vision systems
Industrial artificial vision systems consist of several key elements that work together to capture and analyse images in all kinds of industry. These components are essential to guarantee the system’s efficacy and precision. They are:
Image sensors and cameras
These components might be defined as the “eye” of the industrial artificial vision system. Cameras may vary in type and complexity, ranging from standard digital cameras to other special cameras, such as infrared or 3D. Image sensors are responsible for capturing light and turning it into electronic signals to be processed by the system.
The lighting systems are essential for obtaining clear, consistent images of your products. They include LED lights, fibre optic, and stroboscopic lighting systems, designed to highlight the specific characteristics that need to be inspected.
Lenses are the element that determines the field of vision and resolution of the image captured by the system. Selecting appropriate lenses is an essential step to guarantee that the images captured by the cameras have the right size, focus, and perspective to conduct the analysis.
Software is the key piece in the industrial artificial vision system. It is responsible for analysing the captured images to detect defects, measure dimensions, identify products, and conduct other tasks related to inspection. The software is highly sophisticated, which is why it uses automatic learning algorithms and advanced image processing, so that no flaw or error makes it through your production.
The interface is the element that makes it possible for workers to interact with the artificial vision system to configure parameters, executing inspections and viewing results. It can be as simple as a few buttons, or as complex as complete software with graphic interfaces. All so that your staff, without advanced IT knowledge, can control these systems.
Industrial artificial vision systems must communicate without control systems within the production plant, such as PLCs (Programmable logic controllers) and data management systems. This makes it possible to integrate the industrial vision system into the broader production process.
Here, we would include processors and computers responsible for executing image processing software. The hardware must be powerful enough to quickly analyse images and make decisions in real time.
Uses of industrial artificial vision systems depending on the sector
E2M COUTH knows how important it is to have Industrial artificial vision systems at your plant, regardless of the sector. Here are the different ways you can use them, depending on the products you manufacture:
In the manufacturing field, Industrial artificial vision systems are a basic element for inspecting quality, identifying defects, and guaranteeing the integrity of the end products. Moreover, they carry out a key role in verifying assembly, guaranteeing precision in production.
Within the food industry, Industrial artificial vision systems focus their activity on classifying and selection products. They are responsible for detecting imperfections in food, ensuring quality, and complying with legally established health standards. Their ability to guarantee quality in production is essential for food safety.
In the pharmaceutical field, industrial artificial vision systems are used to inspect medications, guaranteeing compliance with strict manufacturing standards. They detect irregularities in packaging and guarantee precision in the production of pharmaceutical products.
In the beverage industry, these Industrial artificial vision systems are used to classify and verify labels, guaranteeing that the products comply with packaging and presentation standards required for sale to customers. Moreover, they are perfect to detect defects in containers, avoiding issues during packaging and transport.
In the logistical field, these systems are responsible for optimising inventory management by reading bar codes and labels. This provides precise monitoring of merchandise, reducing errors and streamlining storage and distribution processes.
Discover the advantages of artificial vision systems in industrial processes
After explaining how artificial vision systems in industrial processes work, we are going to show you the advantages of using these systems at any industrial plant:
Let us begin with the advantages of artificial vision systems in industrial processes by discussing their ability to adapt to different kinds of tasks. In this regard, you can completely configure the vision system so that it measures the characteristics and parameters of your choosing, adapting to the kind of product you manufacture. This means you can analyse labelling, shape, foreign objects, product orientation, etc.
This is another one of the great advantages of using this kind of system since it analyses all production reliably. This means that you have peace of mind while using the system, since it will not go outside the parameters you have set. This is crucial if you want to compete on today’s market with companies that manufacture products similar to yours.
Let us continue with another one of the great benefits of having an artificial vision system in industrial processes. Speed is a fundamental aspect at any production plant. For this reason, these systems are designed to easily adapt to large production volumes.
At the end of the day, time is a key element at every factory. Remember that if you manage to speed up a process by one second, you can considerably increase total production. In addition to ensuring top quality for all your products, these systems also make it possible to do so more quickly.
Another characteristic of artificial vision system sin industrial processes is that they are flexible and can be installed on equipment in any area of the production line. Moreover, you do not need to train your employees to control the systems, since the systems carry out different calculations and complex operations while analysing the products.
This kind of industrial system is able to detect all kinds of problems before the product reaches the hands of consumers. This is essential to maintain a good image for your clients. You ensure that all the products from your plant meet safety parameters and have no errors worth mentioning in terms of labelling and other situations.
When you control all possible defects in your production, you can improve the production process to avoid excessive expenses during production. You can reduce waste during production. Additionally, when it detects flaws, the system learns from them to avoid repeating them in the future. This also entails economic savings for the company since products need not be tossed due to these flaws.
What are the challenges and limitations of Industrial artificial vision systems?
Artificial vision has become a key point within different industries, but it can also pose some challenges for the future. These include:
Changes in lighting can significantly affect the precision of Industrial artificial vision systems. For this reason, changes in ambient light can make it difficult to detect objects and interpret details. This is an ongoing challenge in dynamic industrial settings.
Calibration and alignment
Precise calibration of these systems is basic to guarantee correct measurements and detection. The need for meticulous alignment can be a challenge, especially in settings where conditions frequently change.
The diverse shapes and characteristics of objects in industrial settings can make it difficult to create universal algorithms. The adaptability of these systems to recognise and classify different objects is an ongoing challenge. Measurements of these objects are, as well.
Cost of implementation
Although the benefits are significant, initial implementation of Industrial artificial vision systems can be costly. Moreover, regular maintenance and software updates are essential, which is an added layer of investment. Even so, it is worth it to have these systems because of the time they save, and the quality results you obtain in your production. Forget about defective products that can harm your brand image to your competitors’ benefit.
In industrial spaces, where speed is very important, system processing capacity can be a limiting factor. The time required to analyse and make decisions is a challenge within highly dynamic processes. Even so, the systems are growing faster and faster, so they can easily handle a higher work volume.
Ongoing training and adaptation
Artificial vision systems require initial training, as well as ongoing adaptation to remain effective. The need for representative training data and the ability to adjust to changes in the environment are challenges the company must face.
How integrating Industrial artificial vision systems has changed everything
Integrating artificial vision systems into industrial automation has radically transformed how companies handle quality, efficiency, and precision in their processes. However, as seen above, this progress is not free from challenges that must be addressed to increase the positive impact.
One crucial aspect in integration is managing variable lighting in industrial settings. The ability of systems to adapt to changing light is essential to maintain consistency in detecting objects and interpreting details. In turn, calibration and precise alignment are critical factors to guarantee exact measurements under changing conditions.
Variability in the shapes and characteristics of objects is another important challenge. The adaptability of systems in recognising a wide range of objects is essential to guarantee universal application in diverse industrial settings. Moreover, processing speed is a key factor, especially in sectors where speed in decision-making is essential.
Despite these challenges, integrating artificial vision systems provides significant advantages. In the manufacturing industry, quality inspection becomes more precise, identifying defects and ensuring the integrity of end products. In logistics, inventory management is optimised, reducing errors and streamlining storage and distribution processes. The ongoing search for solutions in artificial vision for the challenges today leads us down a future path where integrating artificial vision systems will boost the efficiency and quality of automation processes in industry.
Which artificial vision systems for industrial processes do we have at E2M Couth?
After explaining how artificial vision systems work in this sector, as well as the different advantages they can provide, we want to talk about which systems like this we have available in our catalogue. They are:
At E2M, we have inspection systems of excellent quality that can be applied to industrial processes. These devices are able to inspect different elements, such as labels, incorrect packaging, text control, product codes, and other actions.
This kind of system is essential to detect all kinds of flaws and errors in production. By applying these systems to the production line, you can correct any sort of problem you detect. Applying these systems means your factory’s efficiency increases.
Let us move on to another kind of artificial vision system in industrial processes: orientation systems. On a production line, products go by at high speed. They may not be in the correct position, so you need a system like this to keep all containers and products oriented correctly. This way, you can correctly fill and label them and carry out all the other actions related to the product. Our systems can move the container or product 90, 180, and 270 degrees.
At E2M Couth, we know that, after production inspection, it may be that different products should not remain on the production line. In this regard, we have rejection systems to remove any products with flaws or defects. These systems detect any kind of problem and remove the product. Moreover, you have the option of reviewing the problem later to decide whether you can use the products again in the future.
The product rejection systems available at E2M Couth include impact systems for products that are not fragile and that you wish to quickly remove from the production line. Another one of the rejection systems we have available are gentle deviation systems, which are ideal for fragile products. This last rejection system creates a line in parallel to the production line, separating it from products that are correct.
Lastly, another one of the systems available at E2M Couth are product marking systems. The key to these systems is that they allow you to quickly and easily locate products or batches that prove defective. In our catalogue, you can see that we have systems that work with laser technology and can mark and encode different kinds of industrial products.
Get the best artificial vision systems for industrial processes at E2M COUTH
We hope that this post has clarified how to apply artificial vision systems to industrial processes, as well as how important they are at a production plant. It is also important to use them due to increased market competition because you need a high quality standard, as well as very fast production to remain competitive.
At E2M Couth, we have a wide variety of artificial vision systems that you can apply to your industrial production plant. By installing and using them, you can put an end to a great number of problems, ensuring proper labelling, as well as characteristics for these products.
Moreover, we would like to remind you that if you want to learn more about these systems or install them at your production plant, you can contact us and we will be delighted to help you.