Camera-Based Quality Control Systems
Systems that image every product on the line, separate defective products and record every decision.
A camera-based quality control system captures an image of every product passing on the production line, evaluates the image with software and AI, and makes an OK or NOK decision for the product. Defective products are removed by a rejector and every decision is stored with its image. Visual inspection that used to be done by hand is carried out at line speed, with the same criteria on every product.
Specto builds each camera inspection system for the product, the line and the quality criteria. If the plant already has cameras and lighting, the system is integrated with that equipment. If not, the camera, lens, lighting, electronics and software are all selected for the product and supplied.
What does it check?
- Cracks, flash, broken edges and missing operations
- Scratches, dents, stains and colour differences
- Missing parts and wrong assembly
- Caps, labels, date codes and barcodes
- Dimensions, hole positions and tolerances
- Counting, sorting and position
System components
- Industrial camera and lens
- Lighting selected for the product and the defect
- Trigger sensor and, where needed, an encoder
- Vision computer and software
- Air-jet, pusher or diverter rejector
- Operator panel and record keeping
How does it work?
- Step 01
The product reaches the camera
On a sensor or PLC signal, the image is captured while the product is moving.
- Step 02
The image is evaluated
Software and an AI model examine the image against the product’s quality criteria.
- Step 03
A decision is made
An OK or NOK decision and the reject reason are determined for the product.
- Step 04
Defective products are removed
NOK products are taken off the line by the rejector; products that cannot be decided are also removed on the safe side.
- Step 05
Records are kept
Every decision is stored with its image and time; results can be reported and passed to production systems.
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Frequently asked questions
Does a camera-based quality control system slow down the line?
No. The camera, lighting and software are selected for the line’s existing speed. Images are captured while products are moving and the decision is made before the product reaches the reject point.
Can it be installed on our existing line?
Yes. The system is usually added to an existing conveyor or machine. Before installation, the available space, product flow, trigger and reject points and the PLC connection are reviewed on site.
What does the cost of a camera-based quality control system depend on?
It depends on the number of inspection points, camera and lighting needs, product variety, line speed and rejection and integration requirements. The cost becomes clear once the product and samples have been reviewed.
Do production images leave the plant?
No. The system runs inside the plant without an internet connection; images and records stay on site.
Can tests be done before installation?
Yes. Camera and lighting tests are run on good and defective samples, so you can see how clearly defects separate in the image before installation.
Let’s evaluate your project together
Tell us about your product and inspection needs, and we will work out the right system together.