3D Inspection Software (Volume, Height)

For appearance / dimension inspection and positioning using image processing and character recognition using OCR, targets are detected or differentiated based on the shade data of their surfaces. To increase the accuracy of these operations, various measures have been introduced, including the use of high-pixel machine vision, optimization of lenses and lights, and adoption of image enhancement filters and other technologies. Even with the latest technologies, it is still hard to solve certain problems in image inspection, including:

• Differentiating flaws or distortions from discoloration or color irregularity
• Detecting the depth of flaws or distortion level
• Performing pass/fail judgment based on capacity or volume
• Inspecting the profile of solder or welding

Manual inspections are mostly provided by human operators, whose methods are often susceptible to error. These methods severely lack accuracy and precision when compared with 3D dimensional inspection.

The biggest advantage 3D vision systems have over 2D inspections lies in the third dimension. While 2D measures length and width, 3D systems benefit significantly from being able to measure height. This, of course, includes volume, which is derivative of all three dimensions. This is achievable through the use of manual tools, but not as efficiently and accurately as with a 3D machine vision system.

3D machine vision systems, paired with 3D inspection software, excel at object analysis at high speeds, which significantly reduces inspection times compared to manual methods. The increased efficiency is crucial in high-volume production environments, where time savings equal cost savings.

This precision and high efficiency offer consistent and repeatable results, especially when compared to manual inspection methods, which are subjective and vary between operators. This is vital for maintaining quality standards.

Lastly, 3D machine vision systems and 3D inspection software are capable of identifying defects early in the production process, and a 3D inspection system allows for immediate correction, which further reduces waste and eliminates the need for rework.

3D machine vision systems are crucial for the development of Industry 4.0, as they offer exceptionally high accuracy, efficiency, and consistency in measuring volume and height across a range of industries.

Thanks to the unique advantages 3D vision inspection systems offer, many businesses are now using these systems to enhance their manufacturing efficiency and product quality.

For example, their high accuracy, often measured in the single-digit µm range, makes them very useful in industries where precision is paramount. This includes the automotive industry, where these systems are used to verify and inspect dimensions and volumes of complexly shaped components, like engine parts.

The electronic industry has undergone massive miniaturization of components, leading to densely populated circuit boards almost impossible to inspect accurately by hand. The electronics industry relies on 3D machine vision systems, complemented by 3D inspection software, to measure the height and volume of the solder paste applied during the PCB assembly process.

This ensures proper solder paste application and reduces the risks of cold joints. Additionally, these systems are also used to measure the height and position of soldered components, ensuring they’re positioned correctly.

Industries dealing in perishable goods, such as food, beverage, and cosmetic industries, typically rely on 3D inspection to measure the height and volume of their products. This helps with consistency in packaging and detects any physical deformities that could indicate processing errors or contamination in the manufacturing process.

The same applies to aerospace and defense, which rely on 3D vision and 3D inspection software for the inspection of parts and components that are manufactured within exceptionally tight tolerances. KEYENCE's 3D machine vision technology utilizes pattern projection and laser profilers to perform 3D inspections on continuous processes, stationary parts, and objects close to the sensor.

Interested in improving your production efficiency and accuracy? Look no further than KEYENCE’s cutting-edge 3D vision systems. Contact us to learn more about how our advanced technology can help take your manufacturing processes to the next level.