Implemented visual inspection for metal surface defects, with synchronized part tracking and PLC rejection
Delivered System
Surface defects connected to production decisions
We implemented a visual inspection system for metal ends, rings, and domes, connecting surface analysis to tracked rejection on the line. Polar unwrapping and complementary geometric, intensity, and coverage detectors identify rim damage, wrinkles, scratches, paint chips, and sealant discontinuities. Overhead and lateral cameras capture parts at stations before and after flipping, while encoder tracking preserves their identity through the inspection sequence. Defect categories explain each result to operators, and the PLC receives rejection decisions. Testing covered lighting, curled-edge visibility, false rejects, and tracking across representative parts and acquisition conditions.
What we did on it...
Requirements
Mapped defects in real samples
We examined real images of metal ends, rings, and domes to define the inspection categories. Rim damage, wrinkles, scratches, paint chips, and interrupted sealant guided detector development and the selection of views needed to inspect each surface.
Structure
Integrated complementary visual checks
We combined polar unwrapping with geometric, intensity, and coverage detectors to inspect circular features and surface defects. Overhead and lateral cameras were integrated before and after flipping, with encoder synchronization linking each acquired view to its part.
Interface
Connected defects to tracked rejection
We linked inspection findings to encoder-tracked parts and implemented PLC rejection signals. Operators receive defect categories that explain the result, while part identity is maintained through flipping and both stations so each decision follows the correct item.
Validation
Tested acquisition and rejection behavior
We tested image processing, lighting, and tracking with representative metal parts. Validation examined false rejects and internal curled-edge visibility, then checked the connection between inspection findings, part identity, and PLC signals throughout the completed acquisition and rejection workflow.
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