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Quality control

AI Visual Inspection for Defect Identification on conveyor belt

Many recurring activities are being solved by AI-visual inspection and image processing. Particularly useful is this new technology for the manufacturing sector. There are several laborious operations in the manufacturing unit for processing, sorting, and grading materials. Your comprehension of the advantages of automation will be deeper. However, because of sensory limitations, the automatic systems haven’t been implemented correctly. As computer technology progresses through the application of machine learning and artificial intelligence, this situation is beginning to change. Let’s now examine the benefits of AI image processing for creating and growing enterprises.

Conveyor belt quality monitoring using computer vision technology is becoming more and more common in manufacturing and production facilities. This is how it operates:

Image Capture: A camera takes pictures of goods as they move along a conveyor belt. Mounting the camera on a moving platform or fixing it there will allow you to take pictures from various perspectives.

Image Processing: Computer vision algorithms are used to process the camera’s collected images. These algorithms are able to recognize irregularities and flaws in the items, such chips, cracks, or missing parts.

Classification: The products are divided into many groups according to their flaws and quality. Products that are deemed to be of sufficient quality are removed from the line, while those that do not are permitted to stay on the conveyor belt.

Sorting: Various categories can be used to classify defective products according to their nature. This enables manufacturers to find the source of the issue and implement fixes.

Reporting: To enhance production methods and lower errors going forward, data on product quality and flaws can be gathered and examined.

Conveyor belt computer vision identifies irregularities in quality, including color, cracks, and the direction of the moving object.

This application allows for timely quality checking of bolts on a conveyor belt by measuring the object’s length and breadth in millimeters.

Applications for computer vision in quality control on conveyor belts in manufacturing and industrial facilities are numerous. Here are a few particular instances:

Inspection of Product Quality: Product photos taken on a conveyor belt can be analyzed by computer vision algorithms to find flaws like chips, cracks, discolouration, or missing pieces. By doing this, it may be possible to guarantee that only top-notch goods are introduced to the market.

Label Verification: Verifying label and packaging information, including barcodes, expiration dates, and product numbers, is another application for computer vision. By doing this, you can make sure that clients receive the appropriate products in the proper packaging.

Counting and Sorting: Products on a conveyor belt can be counted and sorted using computer vision based on predetermined standards like size, shape, or color. Manufacturers may benefit from this by streamlining their processes and streamlining their supply chain.

Machine Vision Inspection: Conveyor belt machine performance can be examined with the aid of computer vision. Defects like as wear and tear, incorrect assembly, or broken parts can be recognized by the algorithms. By doing this, manufacturing efficiency may be increased and equipment problems can be avoided.

Quality Control Analytics: Data on product quality and flaws can be gathered using computer vision, and then examined to spot patterns and trends. This can assist producers in streamlining their workflow and raising the caliber of their output.

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Quality control

Carbon Soot detection using Custom Object Detection model

Carbon soot, or simply soot, is a black powder of carbon particles formed from incomplete combustion of organic matter like fossil fuels and biomass. It’s a common residue from sources like candles, gas stoves, and vehicle exhaust, contributing to air pollution and posing health risks when inhaled.

Carbon soot can detrimentally impact the nail producing industry by compromising product quality with blemishes, increasing equipment maintenance needs, posing health risks to workers through inhalation, and triggering environmental regulations due to emissions. Controlling soot contamination is crucial to uphold quality, worker safety, and regulatory compliance in nail production. So. this carbon soot should be removed if detected.

Scanflow is an advanced AI scanning tool designed for smart devices, enabling seamless data capture and workflow automation. With the Scanflow application, users can perform tasks such as Quality Checks, ID card identification, Label Scanning, and more. We offer an automated solution to industrial challenges using state-of-the-art technologies.

Here, we’ve developed a real-time solution utilizing a bespoke object detection model to identify carbon soot. This component is an integral part of the automated solution we’ve constructed within Scanflow for our industrial client.

To train an AI model for carbon soot particle recognition, we meticulously separated a video containing the particles into individual image frames, creating a diverse dataset that exposes the model to a wide range of representations for robust learning. The following steps are used to train and test the detection with Jetson Orin Nano.

Carbon soot-containing video data is utilized for training models, with annotation performed via a custom labeling tool. Frames are extracted from the video, then preprocessed and augmented within the tool. This version of the dataset is employed for training and testing the custom object detection model.

We utilized the labeled dataset within the custom labeling tool to train an advanced AI model using a custom object detection algorithm, known for its exceptional speed and accuracy in detecting specific objects within images or videos. This approach streamlined the training process, notably decreasing both time and resource requirements.

After successful training, we deployed the AI model onto the NVIDIA Jetson Orin Nano, a compact and energy-efficient edge computing platform. Initial tests on the Jetson Orin Nano showed promising results, achieving an inference speed of approximately 22–25 frames per second (FPS) in the custom object detection model (largest variant in custom object detection).

Throughout the training process, we faced numerous challenges pertaining to accuracy, detection performance, model size, and layer optimization. Despite our efforts to fine-tune hyper parameters for improved accuracy, and to develop lightweight models suitable for deployment on edge devices, we encountered unexpected environmental factors during real-time testing that adversely affected carbon soot detection. However, we effectively addressed these issues through augmentation techniques and further refinement of the model, ultimately ensuring robust detection capabilities even in challenging environmental conditions.

This demo video, featured on the Scanflow YouTube channel, showcases our custom object detection model in action, detecting carbon soot in real-time setups. The model is implemented on the Jetson Orin Nano devices, offering impressive performance.

In summary, by utilizing custom labeling tool for data collection and annotation, training a custom object detection model with GPU acceleration, and deploying it onto the Jetson Orin Nano for inference, we’ve established an end-to-end pipeline for efficient and accurate object detection in carbon soot-containing video data. This approach not only demonstrates the adaptability of AI models to specific tasks but also showcases the integration of cutting-edge hardware platforms for real-time inference in edge computing environments.

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Quality control

AI-Powered Vision Inspection: How AI Can Transform Your Manufacturing Process

 
Checking the quality of parts manually comes with its challenges. People can get tired and might miss mistakes when staring at numerous parts all day. Human judgment is subjective, and even the best inspectors can make errors, which can lead to bigger issues later. Imagine using faulty parts, resulting in costly re-work, product recalls, and unhappy customers. These hidden costs can seriously impact a company’s profits. For instance, think about airbags failing to deploy due to overlooked defects or a phone catching fire because of a tiny flaw – not a good scenario! Relying solely on manual inspection has its risks and can be expensive.

 
Forget about magnifying glasses and checklists; AI is revolutionizing quality control with unparalleled precision. Picture robots equipped with eagle-eyed cameras that swiftly scan parts, going beyond mere observation to truly “see” and comprehend what they’re inspecting. This AI magic can

Scan anything: From tiny screws to complex machinery, AI vision systems can handle it all.

Verify instantly: No more waiting for human inspectors. AI can quickly check if everything matches the blueprint, flagging any deviations or defects.

Detect hidden flaws: Missed cracks, misaligned parts, even tiny color variations – AI can spot them all, even faster than the human eye.

Automate like a boss: Repetitive tasks? Gone! AI handles them all, freeing up human inspectors for more complex jobs.


 

 
1. Unmatched Accuracy: Forget human error! AI inspectors are like tireless robots, catching every defect, big or small, every single time. They don’t get tired, distracted, or have bad days, ensuring consistent, top-notch quality control.

2. Boosted Efficiency: Time is money, and AI saves both. Imagine inspections happening in seconds, not hours. This frees up your team for more valuable tasks, increases production speed, and minimizes downtime due to faulty parts.

3. Real-Time Insights: AI doesn’t just see problems; it predicts them. By analyzing trends and patterns, it identifies potential issues before they occur, allowing you to take proactive measures and optimize your production process for maximum efficiency.

4. Quantifiable ROI: All these benefits translate into real, measurable results. Reduced rework, fewer recalls, and faster production mean significant cost savings. AI pays for itself, boosting your bottom line and giving you a competitive edge.

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Quality control

Optimize Your Inventory with Scan flow’s component number scanning

 
Ever scribbled a number onto a form and worried whether it would get typed in right? That’s the headache of manual data entry – copying information by hand. It’s slow, like wading through a swamp of numbers and letters. Mistakes happen easily, like typos or misplaced digits, turning your data into a tangled mess. This slows things down, like waiting in line forever, and can even have big consequences, like sending the wrong parts to a factory or forgetting where things are in stock. Imagine a world were scanning a number instantly sends it to the computer, perfectly accurate and lightning fast. That’s the magic of Component Number Scanning – ditching the paper chase and letting your data fly!

 
Remember the hassle of scribbling part numbers on messy forms? Or the fear of mistyping them later? Those days are gone with Scanflow’s Component Number Scanning! Imagine this: you point your smartphone at a printed stencil number, a handwritten code, or even a scratched serial number, and boom! It’s instantly zapped into your computer, accurate and lightning fast. No more typos, no more lost digits, just clean, reliable data ready to work for you.

Scanflow’s magic lies in its versatility. It’s like a superhero with X-ray vision for numbers! It can decode any format, from clear-cut stencils to messy handwriting, even damaged or faded codes. And it’s not picky about devices either. Your trusty smartphone, a handy tablet, or even a wearable on your wrist – Scanflow works with them all!

So, say goodbye to the paper chase and hello to a streamlined workflow. With Scanflow’s Component Number Scanning, you’ll have accurate data at your fingertips, ready to boost your efficiency and make your life easier. Now that’s something to smile about!

 
No More Typo Blues: Remember struggling to read messy handwriting or squinting at tiny numbers? Scanflow zaps them into your computer perfectly, every time. Say goodbye to typos and hello to crystal-clear data!

Trace Every Part Like a Detective: Wondering where that widget went or which batch that bolt came from? Scanflow keeps track, like a super-powered detective, tracing each component from start to finish. No more mystery, just perfect organization!

Inventory Whiz Kid: Tired of stockouts or warehouses overflowing with the wrong stuff? Scanflow is your inventory whisperer, telling you exactly what you have and where it is. No more surprises, just perfect stock control!

Scratches and Fades Don’t Win: Even beat-up numbers and faded codes are no match for Scanflow. It’s like a code-cracking ninja, reading even the toughest markings. No more lost information, just complete data capture!

Work Anytime, Anywhere: Stuck in a field with no computer? No worries! Scanflow works on your phone, tablet, or even a fancy wrist gadget. Work wherever, whenever, and keep your data flowing freely.

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Quality control

How VIN Scanners Can Improve Efficiency in the Automotive Industry

 
Imagine a world where cracked VINs get scanned in a flash, paperwork melts away, and your dealership runs on autopilot. That’s the magic of Scanflow, the AI-powered sidekick that transforms your messy VIN handling into a streamlined symphony. Ditch the typos, the delays, and the headaches. Scanflow’s smart scanners read even the most stubborn VINs, zap the data straight into your systems, and let you focus on what you do best: keeping customers happy and wheels turning. It’s like giving your dealership a superpower – the power of effortless VIN accuracy and efficiency. So, are you ready to say goodbye to manual error and hello to a smoother, smarter future with Scanflow.

 
The vehicle VIN, a unique 17-character code, is like a secret key. It tells the whole story of the car, from where it came to who owns it now. But handling this code the old way, with pen and paper, can be a real mess.

Imagine a busy vehicle dealership, where workers scribble VINs on forms, their fingers hovering over keyboards, eyes squinting at faded numbers on sun-baked dashboards. It’s a recipe for mistakes! One tiny typo can mix up the whole car’s identity, leading to lost vehicles and angry customers.

These errors aren’t just annoying, they can be costly. A wrong number can mess up car counts, delay repairs, and even avoid warranties. And the worst part? It opens the door for fraud!

So, what’s the fix? Ditch the pen and paper and let machines do the work! Automated VIN scanners powered by AI can capture the code instantly and accurately, without any typos or squinting. This is the future of VIN handling, where mistakes are a thing of the past. The days of VIN-caused chaos are over, thanks to the magic of automation!

 
Say goodbye to the days of squinting at blurry VINs and battling typos! Scanflow unveils a revolutionary approach to VIN handling, powered by cutting-edge technology and AI smarts. Here’s how it redefines the game:

1. Seamless Capture: No more struggling with damaged or obscured VINs. Scanflow’s advanced scanners boast lightning-fast reading, even on scratched, faded, or partially covered codes. Whether it’s baked under the hood or hiding in a dark corner, Scanflow captures it all, instantly and accurately.2. Data Integration: Forget the manual data entry dance. Scanflow seamlessly integrates with your existing dealership workflows. The captured VIN data is instantly zapped into your systems, automatically updating records, creating service orders, and streamlining every step of the process. No more double-entry purgatory, just smooth, real-time data flow.

3. Automated Tasks: Ditch the paper forms and repetitive keystrokes. Scanflow automates tedious tasks like VIN verification and data entry. This frees up your staff to focus on what truly matters: delivering exceptional customer service, attending to repairs, and ensuring smooth operations. Every minute saved is a minute earned for your dealership’s success.

Scanflow isn’t just about speed and accuracy; it’s about empowering your dealership to operate at peak efficiency. By eliminating manual errors, streamlining workflows, and freeing up valuable time, Scanflow unlocks a world of possibilities. Imagine a dealership where VINs are a breeze, paperwork melts away, and your staff can focus on what they do best – making your customers happy and keeping your business thriving. That’s the power of Scanflow, the AI-powered solution that transforms VIN handling from a chore to a seamless superpower.

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Quality control

Transforming Production: How AI Eliminated Defects in Vehicle Cockpits

In the fast-paced world of manufacturing, achieving flawless production is a constant challenge. Every component matter, and even minor inconsistencies can lead to costly delays, recalls, and reputational damage. The manufacturer, precisely facing this issue, sought a revolutionary solution to ensure the highest quality standards in their intricate assembly lines.

 
The manufacturer relied on traditional manual inspection methods. This process involved human inspectors meticulously checking each individual component, switch, and button across multiple units. However, this approach suffered from several shortcomings:

  • Human error: Fatigue, individual variation, and human oversight could lead to inconsistencies and missed defects.
  • Time-consuming: Manual inspection added significant time to the production line, impacting efficiency and throughput.
  • Limited scalability: As product complexity increased with more components and variations, the manual process became cumbersome and unsustainable.

 
In a stroke of innovation, the manufacturer partnered with a tech company to develop an AI-powered switch inspection system. This cutting-edge solution leveraged:

  • Sharp Vision: A trained AI model accurately identified truck models and individual switches based on scanned build cards and cockpit layouts.
  • Eagle-Eyed Inspection: The model scanned each switch within designated grids, comparing them to its database of “correct” configurations.
  • Instant Red Flags: Any deviation from the expected setup was instantly flagged, enabling immediate corrective action before defective vehicles entered production.
  • Enhanced accuracy: Eliminate human error and ensure consistent, objective quality control.
  • Increased efficiency: Automate time-consuming inspections and significantly reduce production line bottlenecks.
  • Boosted scalability: Easily adapt to different models and component variations, future-proofing quality control.
  • Cost reduction: Minimize defect rates and recalls, lowering overall production costs.

Scanflow - AI Scanner Team

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