Defect detection determines the success or failure of the automated visual inspection station

The VIS-I solution is a complete, integrated inspection station that combines Radiant Vision Systems' ProMetric® imaging luminance meter or colorimeter, brightfield illumination, and customizable inspection software. This advanced system is designed to detect complex component assemblies and subtle surface defects that may be difficult for the human eye to spot. It can be seamlessly integrated into the production line for real-time inspections, offering greater accuracy and consistency compared to manual inspectors and traditional machine vision systems. The compact design of the VIS-I only takes up the space required by a single operator, making it an efficient and practical addition to any manufacturing environment.

The VIS-I system not only identifies defects but also tracks them using serial numbers, recording detailed data on defect types, trends, and locations. With a comprehensive set of tools from Radiant's TrueTest™ automated vision inspection software, the system can perform multiple machine vision tasks—such as positioning, counting, measuring, and OCR—either simultaneously or in sequence, ensuring thorough and reliable results.

Replicate the detection and judgment ability of the human eye

In many manufacturing settings, traditional machine vision systems fall short because they lack the nuanced perception of human inspectors. The VIS-I system bridges this gap by combining the precision of automation with the sensitivity of human vision. It’s ideal for environments where both high accuracy and efficiency are required, offering a powerful alternative to manual inspection without the associated fatigue and inconsistency.

Human inspectors are skilled at identifying subtle defects and determining whether they fall within acceptable tolerances. However, prolonged work on complex parts can lead to fatigue, reducing their accuracy over time. While additional staff can help, it’s costly and inefficient. The VIS-I system offers a more sustainable solution, delivering consistent performance with absolute accuracy and reliability. Its calibration mimics human visual sensitivity, enabling it to detect a wide range of subtle features without repeated checks. The system also uses advanced logic to determine pass/fail outcomes based on specific defect tolerances, providing objective and repeatable results that outperform manual methods.

Unparalleled camera resolution and dynamic range

High-quality image acquisition is essential for effective machine vision systems. The VIS-I leverages the ProMetric imaging luminance meter and colorimeter, which offer up to 29 million pixels of resolution and a dynamic range of 73.4 dB. This ensures exceptional image clarity, allowing the system to capture even the smallest details and subtle changes on part surfaces. The high-resolution CCD sensor also reduces noise through interlaced cooling, maintaining sharpness and speed during processing.

This combination of high resolution and dynamic range allows the VIS-I to detect fine surface details such as hairline scratches or reflections that might be missed by human inspectors. It can identify tiny defects like micro-scratches on glass, gaps less than 1 mm between keys on a keyboard, or even missing black screws in dark parts. The system provides highly accurate and repeatable results, meeting the stringent requirements of high-value and high-risk product manufacturing.

Image analysis based on luminance meter

The VIS-I system uses Radiant Vision Systems’ industry-leading optical measurement software, enabling it to analyze components in the same way as light characterization. This means it can detect even the smallest visible differences in light uniformity, helping identify abnormal contrast changes. Unlike manual inspectors, the VIS-I can accurately detect and classify specific defects, assigning values to each one based on severity, extent, and tolerance ranges. The system can operate independently or support manual verification in applications where human oversight is still needed.

The system can be directly installed on the production line, with an adjustable frame that accommodates conveyor belts ranging from 525 mm to 950 mm. The total footprint is just 1860 mm (H) x 800 mm (W) x 700 mm (D), matching the space occupied by a manual inspector. The ProMetric camera and lighting are all enclosed within the VIS-I unit, minimizing interference and eliminating ambient light effects. This setup ensures high-contrast images and reliable detection. The system supports line speeds of up to 122 mm (0.4 ft) per second, with part intervals as short as 7 seconds.

Specially designed to meet different inspection needs

Every successful machine vision installation requires a tailored approach. Radiant’s application engineers collaborate closely with customers to customize the VIS-I system according to their specific needs. Each VIS-I is unique, with adjustable height, integrated lighting, and flexible camera options. Manufacturers can choose between monochrome or color imaging solutions depending on their application. All cameras are compatible with Radiant’s TrueTest software, giving access to a full suite of image analysis tools.

Complete machine vision tool library with extensively validated test sequencing software

Powered by Radiant’s TrueTest™ software, the VIS-I system includes a comprehensive library of machine vision tools. These tools perform a wide range of functions, from basic positioning and measurement to advanced presence/absence detection and edge analysis. They ensure precise manufacturing of devices and their components, supporting quality control across various industries.

By leveraging high-resolution imaging and advanced luminance-based evaluation, the VIS-I can detect surface anomalies like scratches, dents, spots, and foreign objects. It uses gradient and contrast analysis to locate and identify subtle defects that traditional systems might miss, preventing potential failures before products leave the factory.

Figure 1. The VIS-I software performs multiple inspections simultaneously, identifying various assemblies and surface defects in a single image and conducting pass/fail analysis based on defined tolerances.

Figure 2. The VIS-I detects subtle defects such as wire placement errors. If wires deviate from their intended path, it could lead to product failure during use.

Main features and highlights of the product:

• Evaluate product quality with greater precision and consistency than manual inspectors performing repetitive testing.

• Track defect trends and classify defects by type, test, or location to assess severity and extent.

• Match human perception in detecting low-contrast defects and identifying components.

• Automated online inspection requiring only the space of a manual inspector on the production line.

• Operate 24/7 with high repeatability and reliability.

• Inspect large products with a single image for accurate measurements.

• Set complex pass/fail criteria for each specific inspection application using the analysis software.

Typical applications:

The VIS-I system combines high-resolution imaging with a powerful machine vision software library to detect defects that traditional systems often miss. It can be installed directly on the production line, supporting continuous operations while addressing various applications, including:

• Subassembly verification: checking the presence, location, and routing of wires, cables, fasteners, connectors, and internal components.

• Total assembly verification: inspecting gaps, steps, bonding, aperture alignment, label quality, and placement.

• Appearance quality control: identifying scratches, dents, fingerprints, dust, bubbles, and point defects.

• Product tracking, reporting, and record-keeping for process control.