automatica 2023

Marie Saverino,

Artificial intelligence in industrial image processing

Recent advances in AI-based image analysis make machine vision accessible to companies of all sizes, even without technical experience or programming knowledge. This reduces the time required to set up inspection applications and increases the efficiency of production lines.

© Cognex

State-of-the-art intelligent vision not only makes the implementation and use of vision and barcode scanning systems easier than ever before, but also improves quality control, optimizes material and energy consumption and increases traceability and productivity.

A vision system can handle a wide range of applications: It can detect defects on products, check final assembly, count parts, record dimensions and much more. In contrast to manual inspections, machine vision works 24 hours a day with consistent performance and offers greater precision and speed.

Deep learning for complex applications

Based on neural networks, deep learning teaches robots and machines to do what humans take for granted: learn from examples. The use cases for artificial intelligence are becoming increasingly diverse, as shown by speech, text and facial recognition based on deep learning technologies.

Edge computing complements centralized cloud-based analytics by providing computing power directly to production lines and logistics operations to quickly collect data and gain context-rich insights. © Cognex

In manufacturing processes, this technology is proving relevant for quality inspections and other judgment-based tasks. Deep learning is particularly suitable for complex applications such as inspecting for unpredictable cosmetic deviations. For example, the detection of defects such as scratches and dents on parts that are turned, brushed or shiny.

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Deep learning in image processing makes it possible to detect anomalies while tolerating natural deviations. Solutions that use this technology can continuously improve their performance by learning from new texts and images.

In some cases (e.g. qualitative interpretation of a complex scene), human vision may be the best choice, but deep learning can overcome the challenges of judgment-based inspection more effectively than a human inspector or traditional machine vision.

Use of AI for smaller companies

While the successful implementation of deep learning-based image processing projects requires planning, knowledge and dedicated resources, AI-based image analysis is now accessible to smaller companies thanks to the recent development of a technology called edge learning. Edge learning is a subset of deep learning, or artificial intelligence, that allows information to be processed directly on the device. This technology has many advantages.

Image processing systems can check the completeness of goods in logistics, in the pharmaceutical industry, in electronics production, in the manufacture of consumer products or foodstuffs and in many other areas. © Cognex

It is easy to use. No specialized knowledge of machine vision or artificial intelligence is required to set up and use an edge learning-based vision solution. Since the algorithms are pre-trained, edge learning takes less time and only five to ten images to learn how to distinguish unacceptable from acceptable parts.

Key to Industry 4.0

Traceability, which is primarily dictated by regulations in the food and pharmaceutical industries, is also becoming increasingly important in other sectors. It makes it possible to track a part, product or packaging throughout its entire life cycle and is therefore one of the most important issues in the entire supply chain.

Image processing tools that work on the basis of AI simplify applications such as reading clear text on challenging backgrounds. © Cognex

Two different technologies are available to capture the information contained in a barcode: laser-based and camera-based barcode scanners. In contrast to laser-based scanners, camera-based scanners combine visualization and image analysis functions in real time for each barcode. They work with advanced decoding algorithms and lighting options and are able to read multiple 1D and 2D symbologies as well as codes marked directly on parts. They can handle even the most difficult codes on challenging surfaces, including shiny, reflective surfaces.

By combining this technology with edge computing platforms, companies can take their traceability processes to the next level by using centralized, cloud-based analytics right alongside production lines and logistics processes. The data collected from barcode scanners throughout the facility helps to identify and understand potential issues, such as misread barcodes, in order to take remedial action as quickly as possible.

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