Top 5 Manufacturing Applications of Machine Vision

MACHINE_VISION
Machine vision is becoming increasingly prevalent in manufacturing daily across industries. The machine vision manufacturing practice provides image-based automated inspection and analysis for various applications, including automatic inspection, process control, and robot guiding, often found in the manufacturing business.

This breakthrough in manufacturing technology enables producers to be more innovative and productive to meet customer expectations and deliver the best products on the market.

A renowned industry leader Mr. Matt Mongonce conveyed in an interview with Media7,

As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity

-Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca.

 

Why is Machine Vision so Critical?

The machine vision manufacturing process is entirely automated, with no human intervention on the shop floor. Thus, in a manufacturing process, machine vision adds significant safety and operational benefits. Additionally, it eliminates human contamination in production operations where cleanliness is critical.

For instance, the healthcare business cannot afford human contamination in some circumstances to ensure the safety of medicines. Second, the chemical business is prohibited from allowing individuals to come into touch with chemicals for the sake of worker safety. Thus, machine vision is vital in these instances, so it is critical to integrate machine vision systems into your production process.

 

Machine Vision Application Examples

To better understand how businesses are utilizing machine vision in production, we will look at five cases.

 

Predictive Upkeep

Even a few seconds of production line downtime might result in a significant financial loss in the manufacturing industry. Machine vision systems are used in industrial processes to assist manufacturers in predicting flaws or problems in the production line before the system failure. This machine vision capability enables manufacturing processes to avoid breakdowns or failures in the middle of the manufacturing process.

 

How is FANUC America Corporation Avoiding the Production Line Downtime with ROBOGUIDE and ZDT?

FANUC is a United States-based firm that is a market leader in robotics and ROBOMACHINE technology, with over 25 million units deployed worldwide. In addition, the company's professionals have created two products that are pretty popular in the manufacturing industry: ROBOGUIDE and ZDT (Zero Down Time).
 
These two standout products assist manufacturers in developing, monitoring, and managing production line automation. As a result, producers can enhance production, improve quality, and maximize profitability while remaining competitive.

 

Inspection of Packages

To ensure the greatest possible quality of products for their target consumer groups, manufacturers must have a method in place that enables them to inspect each corner of their product. Machine vision improves the manufacturing process and inspects each product in detail using an automated procedure.

This technology has been used in many industries, including healthcare, automation, and electronics. Manufacturers can detect faults, cracks, or any other defect in the product that is not visible to the naked eye using machine vision systems. The machine vision system detects these faults in the products and transmits the information to the computer, notifying the appropriate person during the manufacturing process.

 

Assembly of Products and Components

The application of machine vision to industrial processes involves component assembly to create a complete product from a collection of small components. Automation, electronics manufacturing, healthcare (medicine and medical equipment manufacturing), and others are the industries that utilize the machine vision system in their manufacturing process. Additionally, the machine vision system aids worker safety during the manufacturing process by enhancing existing safety procedures.

 

Defect Elimination

Manufacturers are constantly endeavoring to release products that are devoid of flaws or difficulties. However, manually verifying each product is no longer practicable for anybody involved in the manufacturing process, as production counts have risen dramatically in every manufacturing organization. This is where machine vision systems come into play, performing accurate quality inspections and assisting producers in delivering defect-free items to their target clients.

 

Barcode Scanning

Earlier in the PCB penalization process, where numerous identical PCBs were made on a single panel, barcodes were used to separate or identify the PCBs manually by humans. This was a time-consuming and error-prone process for the electronics manufacturing industry. This task is subsequently taken over by a machine vision system, in which each circuit is segregated and uniquely identified using a robotics machine or a machine vision system. The high-tech machine vision system "Panel Scan" is one example of a machine vision system that simplifies the PCB tracing procedure.

 

Final Words

The use of machine vision in the manufacturing business enables firms to develop more accurate and complete manufacturing processes capable of producing flawless products. Incorporating machine vision into manufacturing becomes a component of advanced manufacturing, which is projected to be the future of manufacturing in 2022. Maintain current production trends and increase your business revenue by offering the highest-quality items using a machine vision system.

 

FAQ


What is the difference between computer vision and machine vision?

Traditionally, computer vision has been used to automate image processing, but machine vision is applied to real-world interfaces such as a factory line.


Where does machine vision come into play?

Machine vision is critical in the quality control of any product or manufacturing process. It detects flaws, cracks, or any blemishes in a physical product. Additionally, it can verify the precision and accuracy of any component or part throughout product assembly.

What are the fundamental components of a machine vision system?

A machine vision system's primary components are lighting, a lens, an image sensor, vision processing, and communications.

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MaxLinear, Inc. a leading provider of high-speed interconnect ICs enabling data center, metro, and wireless transport networks, announced the availability of a comprehensive product design kit (PDK) to optimize performance and accelerate the time to market for high-speed Active Electrical Cables (AEC) using MaxLinear’s 5nm PAM4 DSP, Keystone. The PDK is a cost-cutting and time-saving tool for cable manufacturers who want to quickly integrate Keystone into their active electrical cables. MaxLinear’s Keystone PAM4 DSP offers a significant power advantage in AEC applications, which is increasingly becoming a critical factor for hyperscale data centers. The use of 5nm CMOS technology enables designers and manufacturers to build high-speed cables that meet the need for low power, highly integrated, high performance interconnect solutions that will drive the next generation of hyperscale cloud networks. Manufacturers taking advantage of MaxLinear’s PDK to optimize cable designs using Keystone PAM4 DSP will gain a distinct advantage over competitor solutions when trying to maximize reach and minimize power consumption. The PDK makes Keystone easy to integrate with strong applications support, multiple tools to optimize and monitor performance, and reference designs (SW and HW) to accelerate integration. Sophisticated software allows for quick design optimization for the lowest possible power consumption and maximizing cable reach. Cable designers can constantly monitor performance, route signals from any port to any port, and take advantage of hitless firmware upgrades. “MaxLinear is focused on providing not only industry-leading interconnect technologies but also a comprehensive suite of tools to support our manufacturing and design partners,” said Drew Guckenberger, Vice President of High Speed Interconnect at MaxLinear. “Our development kit for our Keystone products provides them with a path to take products to market more quickly and more cost-effectively.” Active electrical cables (AECs) are revolutionizing data center connections. Unlike passive cables, they actively boost signals, allowing for longer distances (up to 7 meters for 400G), higher bandwidth, and thinner, lighter cables. This makes them ideal for high-speed applications like top-of-rack connections (connecting switches to servers within the same rack); direct digital control (enabling flexible interconnectivity within racks and across rows); and breakout solutions (splitting high-speed connections into multiple lower-speed channels). The high-speed interconnect market – which includes active optical cables, active electrical cables, direct attach copper cables, and others – is expected to grow to $17.1B by 2028, up from $10.7B in 2021 according to a market forecast report from The Insight Partners. The Keystone Family The Keystone 5nm DSP family caters to 400G and 800G applications, featuring a groundbreaking 106.25Gbps host side electrical I/O, aligning with the line side interface rate. Available variants support single-mode optics (EML and SiPh), multimode optics and Active Electrical Cables (AECs), offering comprehensive solutions with companion TIAs. Host side interfaces cover ethernet rates of 25G, 50G, and 100G per lane over C2M, MR, and LR host channels. The line side interfaces, tailored for 100G/λ DR, FR, and LR applications, also support these rates. These devices boast extensive DSP functionality, encompassing line-side transmitter DPD, TX FIR, receiver FFE, and DFE. With exceptional performance and signal integrity, these DSPs occupy a compact footprint (12mm x 13mm), ideal for next-gen module form-factors like QSFP-DD800 and OSFP800. Additionally, they are available as Known Good Die (KGD) for denser applications, such as OSFP-XD. About MaxLinear, Inc. MaxLinear, Inc. is a leading provider of radio frequency (RF), analog, digital, and mixed-signal integrated circuits for access and connectivity, wired and wireless infrastructure, and industrial and multimarket applications. MaxLinear is headquartered in Carlsbad, California. MaxLinear, the MaxLinear logo, any other MaxLinear trademarks are all property of MaxLinear, Inc. or one of MaxLinear's subsidiaries in the U.S.A. and other countries. All rights reserved.

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Manufacturing Technology

Detroit Manufacturing Systems Strikes Partnership with InductEV to Accelerate Adoption of High-Power Wireless Charging for Commercial Vehicles

Detroit Manufacturing Systems (DMS) | January 11, 2024

Wireless commercial vehicle charging took a big step forward with an agreement between Detroit Manufacturing Systems and InductEV. In the landmark agreement, DMS, a large-scale, U.S.-based assembly provider, will bring its operations, manufacturing, quality by design, and supply chain expertise to InductEV allowing the latter to more quickly scale to meet customer demand. InductEV is reinventing how electric commercial fleet vehicles charge their batteries by charging on route, using clean renewable electricity. With its wireless induction solution now deployed worldwide and with 18 patents granted and 23 in process, the King of Prussia, PA-based company is the global leader in high-power, high-speed wireless EV charging and AI-software powered energy management. Under the terms of this agreement, DMS will Manufacture InductEV's hardware, including in-ground and under-vehicle inductive pads. Manage InductEV's supply chain and procurement. Utilize engineering expertise to facilitate high quality, design for manufacturing and assembly. Co-develop design optimizations to prepare for a 100-fold increase in production volume. "We couldn't be more pleased to have a manufacturing partner, known for its high standards and operating rigor, combine forces with our proprietary engineering," said Barry Libert, Chairman and CEO, InductEV. "Our complementary areas of expertise will enable us to meet the growing demand from commercial fleet owners and operators, as well as Intermodal facilities and Ports, for our advanced, AI-managed wireless charging solution." Among its product offerings, Detroit Manufacturing Systems currently handles manufacturing for the Ford EV F-150 Lightning signaling its expertise in advanced electric vehicle components and systems production. InductEV's patented technology is currently being used in locations throughout North America and Europe, including in Washington State, Indianapolis, Martha's Vineyard, and in Gothenburg, Sweden, Volvo's hometown. (Volvo Ventures is an InductEV investor.) The company is poised to announce the largest commitment by a U.S. port facility to its wireless charging technology. "We recognize and applaud InductEV's efforts to wirelessly electrify commercial fleets, the biggest contributor in transportation to greenhouse gas emissions worldwide," added Bruce Smith, Chairman and CEO, Detroit Manufacturing Systems. "We look forward to bringing our manufacturing, quality and supply chain expertise to this partnership and creating a successful venture that will help reduce this sector's carbon footprint at a considerable cost savings for all involved." InductEV's proprietary, on-route wireless charging solution shifts EV charging to daytime use of renewables. It reduces the need for large EV batteries, lowering vehicle costs, and eliminates the need for recycling by extending battery life by a factor of 4-8X. Wireless charging also enables the broad deployment of autonomous vehicles. About InductEV InductEV is revolutionizing how electric commercial fleet vehicles charge their batteries. With its proprietary on-route wireless solution now deployed throughout North America and Europe and with 18 U.S. patents and 23 pending, the King of Prussia, PA-based company is the global leader in high-power, high-speed wireless EV charging and AI-software powered energy management. The company just opened one of world's first R&D centers for wireless vehicle charging. About Detroit Manufacturing Systems (DMS) Detroit Manufacturing Systems (DMS) is a contract manufacturing and assembly company that is committed to and is constantly striving for manufacturing excellence and perfect quality. This is achieved through meticulous mistake proofing and a culture of continuous improvement. DMS' GIFTED & RICH fundamental beliefs, management principles, and core values guide the staff in proactively and transparently engaging with customers and suppliers. DMS is also committed to protecting the local and global environment and minimizing the environmental impacts concerning their activities, products and services.

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