Optical Defect Detection
Defect detection encompasses all applications that aim to detect defects and mark the products concerned as “not OK” (NOK). Using proactive, automated defect detection in real time, manufacturers can improve product quality by identifying defective products and goods at an early stage and sorting them out or reworking them. This process reduces downtimes, improves capacity utilization, and lowers production costs.
Automated solutions for quality control are characterized by high reliability and a wide range of application possibilities. They detect scratches in surfaces as well as broken edges or incorrectly positioned labels or parts. This even applies to situations where manual inspections reach their limits.
Various technologies are used depending on the type and characteristics of the products and the production conditions. There are many factors to consider when choosing the right automation solution – contrast, dimensions and position of the defect as well as the speed of the production line. Find out below how the solutions from SICK can help you with automated detection.
Detection of defects on the surface
Automated defect detection plays a key role in the manufacturing industry as a means of identifying surface defects such as scratches, dents or color deviations early. This ensures a consistently high product quality and less scrap. In the consumer goods industry, automated defect detection can be used to identify irregularities in the packaging and the product surface. In food production, it is used for example to check the desired browning level in baked goods manufacturing or to separate out spoiled food. When producing electronic components, surfaces can be precisely checked for damage – a decisive prerequisite for the reliable functioning of electronic devices. Automated defect detection solutions are also used for the cosmetic inspection of surfaces – like paint finishes and the plastic parts of vehicle components or electronic devices. Here they ensure high quality standards and guarantee that the product complies with the aesthetic requirements.
Detecting defects in contour and shape
Detecting errors in the contour and shape of products or components is a cross-industry challenge. The purpose of automated defect detection is to identify broken off or missing parts as well as faulty product shapes. Overhangs can also be reliably detected. In the consumer goods industry, automated defect detection systems check products and packaging for deviations in shape and contour. These ensure that products comply with the prescribed standards and function properly. In the food industry, the systems detect defects such as broken off or missing parts of biscuits or chocolate candies. When producing electronic components, automated solutions monitor, for example, the printed circuit board manufacturing process to identify irregularities such as missing solder joints or damaged tracks. When producing microchips and electronic components, the exact shape and contour of individual elements is of paramount importance. Defect detection systems identify deviations that can arise due to production errors or contamination. In automotive manufacturing, on the other hand, checking the contour and shape of vehicle components such as plastic parts or body parts is essential for the aesthetic quality and structural integrity.
Detection of position defects
Precise positioning of components is of key importance in the entire manufacturing industry. Automated defect detection systems make sure that parts are positioned correctly and thereby ensure a high production quality and efficiency. Incorrectly positioned, mounted or filled products can cause significant problems in downstream processes. In the food and packaging industry, defect detection solutions check whether fillings (e.g. in biscuits), labels or also lids are positioned correctly. In electronics manufacturing, it is important that components are positioned precisely on printed circuit boards. For vehicle components in the automotive industry, parts must be mounted correctly to ensure the quality and safety of the vehicles.
Chain Watch - Inspection system for chain links in conveyor systems
In vehicle production, there is a high risk of chain breakage in chain conveyor systems. There are many potential causes of this: wear and tear, material defects in the chain links and incorrect tensioning as well as lack of lubrication or external damage. A chain breakage can lead to production outages and to safety risks to people and the environment. A crack can be present for months before the damaged chain link finally breaks. To curb this risk, it is necessary to regularly and reliably inspect the chain links in conveyor systems. Manual visual inspection, however, is time-consuming and only possible when the conveyor system is stationary, which results in undesired downtimes. This method is also prone to error and less precise. Chain links of various sizes and shapes are used that operate at different production speeds and are contaminated by oil and dirt.