LINKWIN Case Study: Empowering Manufacturing, Outstanding Practice of Industrial Vision in Quality Inspection
2025-02-14
Guide:
This guide: The article mainly focuses on three aspects: "the current development status of industrial vision inspection, the basic technologies of industrial vision inspection, and LINKWIN case sharing"; the case will show the industrial vision solution provided for a world-renowned large energy and chemical enterprise.
一、 Current Development Status of Industrial Vision Inspection
Industrial Vision Systems are image recognition machines used for automatic inspection, workpiece processing and assembly automation, as well as the control and monitoring of production processes.
In precision manufacturing, there are various processing methods for industrial parts, and the technology is already mature. However, there are still challenges in processing complex or difficult-to-process materials, such as processing damages like scratches, which affect their appearance and, in severe cases, their functionality. Traditional inspection methods can no longer meet the current requirements for precision and efficiency, and more accurate industrial vision inspection technology is needed for detection, measurement, identification and positioning.
In recent years, against the background of intelligent manufacturing, industrial vision inspection, as a core technology, is developing towards higher precision, higher speed and more application scenarios, involving multiple technologies such as optics, algorithms, hardware and software. The application of industrial vision technology is of great significance for the intelligence of the manufacturing industry and the improvement of supply chain resilience.
Advanced technologies such as advanced sensors, high-speed processors and machine learning algorithms provide more powerful hardware support and intelligent image analysis capabilities for industrial vision inspection, matching the manufacturing industry's needs for quality control, production efficiency and cost savings.
二、Introduction to Basic Technologies of Industrial Vision Inspection
Industrial vision inspection is the cross-integration and comprehensive application of multiple technologies such as perception, computing and machinery. The relevant basic technologies mainly include the following aspects:
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Image Acquisition Technology:Image acquisition includes hardware equipment such as industrial cameras, optical lenses, light sources and light source controllers, which perform high-quality imaging of the detected object to obtain one or more images. The precision and detail clarity of the collected images directly determine the accuracy of visual inspection.
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Image Processing TechnologyImage processing includes two parts: hardware that provides computing power and algorithms that perform image analysis. Traditional machine learning algorithms need to rely on logical rules to achieve defect detection on the basis of feature extraction, which is difficult to deal with irregular and diverse features and is being replaced by AI algorithms based on deep learning.
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Hardware TechnologyThe visual inspection system includes hardware such as PLC, robotic arms, slide rails, servo motors and fixtures, which are responsible for controlling the movement of the object to be inspected or the acquisition equipment, including lifting, rotating, flipping and other operations.
三、LINKWIN Case Sharing
Enterprise Profile
The enterprise is a world-renowned large multinational oil and gas company, with business in more than 200 countries and regions around the world, covering multiple fields such as oil and gas exploration and development, oil refining, and chemical industry. Its chemical product production is in a leading position in the world, with a wide range of products, including plastics, chemical fertilizers, synthetic rubber, etc.
It invests a lot of money in R&D every year, committed to improving business operation efficiency and environmental sustainability. Its R&D fields are extensive, including new exploration and production technologies, energy efficiency, renewable energy, etc.
Solution Overview: Application of Industrial Vision in Bottle Cap Quality Inspection
Visual Inspection Schematic Diagram
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视觉检测示意图
🔺Detection of Presence/Absence of Bottle Caps
The camera captures images of the products to be inspected, and the image recognition algorithm analyzes the images. For the detection of the presence or absence of bottle caps, the system pre-learns the image features of products with and without bottle caps, and judges whether the bottle cap exists by comparing the current image with these features.
Advantages: Compared with manual inspection, the visual inspection system can achieve high-speed and continuous inspection, and the inspection accuracy is not affected by human factors, which greatly improves inspection efficiency and accuracy, and can effectively avoid products without bottle caps flowing into the market due to human negligence.
🔺Detection of Bottle Cap Damage
A high-resolution camera is used to obtain detailed images of the bottle cap surface, and image processing technology is used to perform edge detection, texture analysis, etc. on the images. The system compares the collected bottle cap images with the pre-set standard images of intact bottle caps to find abnormal edges, holes or missing parts in the images. If discontinuous edges or abnormal texture interruptions are found in the bottle cap image, it can be judged that the bottle cap is damaged.
Advantages: It can accurately identify minor damages of bottle caps, even tiny cracks that are difficult to detect with the naked eye, ensuring that only undamaged bottle cap products meet the quality standards, and reducing product leakage and other problems caused by bottle cap damage.
🔺Detection of Bottle Cap Flatness
Working Principle: By projecting structured light or laser beams onto the bottle cap surface, the camera captures images of the reflected light from a specific angle, and calculates the 3D topography data of the bottle cap surface according to the light distortion. The obtained 3D data is compared with the model of a standard flat bottle cap to analyze the flatness deviation of the bottle cap surface.
Advantages: It can quickly and accurately measure the flatness of the bottle cap, provide real-time feedback for the production process, adjust the production process in a timely manner, ensure the tightness of the bottle cap, and prevent the product quality from being affected by poor sealing caused by uneven bottle caps.
🔺Detection of Correctness and Completeness of Bottle Cap Text
Optical Character Recognition (OCR) technology and image matching algorithms are used. The camera takes images of the text on the bottle cap surface, preprocesses the images to enhance the clarity and contrast of the text. OCR technology is used to convert the text in the image into recognizable characters, which are compared with the pre-set correct text content. At the same time, the completeness of the text is checked through image matching algorithms to judge whether the text is missing, blurred or wrong.
Advantages: It can efficiently and quickly perform text detection on a large number of bottle caps, ensure the accuracy and standardization of product labels, help enhance brand image, and avoid text errors or incompleteness.
🔺Detection of Correct Bottle Cap Color
Working Principle: Color recognition technology is used. The camera is equipped with a sensor with color perception capability to obtain the color information of the bottle cap. The system compares the collected bottle cap color data with the pre-set standard color samples, and judges whether the bottle cap color is correct by calculating the color similarity. Color space models such as RGB and HSV are usually used to quantify color information. If the color deviation exceeds the set threshold, the system determines that the bottle cap color is wrong.
Advantages: It can accurately identify the color of the bottle cap, ensure the consistency of the product's appearance color, meet the brand's strict requirements on product appearance, and improve the overall visual quality of the product.
Project Application Value
After applying the industrial vision inspection system, the enterprise has created outstanding value. In terms of quality control, it has achieved high-precision inspection of product details with highly consistent inspection standards, not affected by human factors, ensuring stable product quality; in terms of production efficiency improvement, its inspection speed is far higher than that of manual work, which can be seamlessly connected with high-speed production lines, timely warn of quality problems, and reduce downtime; in terms of cost control, it has greatly reduced labor costs, avoided quality problems caused by manual inspection errors, optimized the production process by analyzing inspection data, reduced product scrap rate, and improved raw material utilization rate.
About Us
Founded in 2001, LINKWIN is a world-leading technology company specializing in digital services and smart IoT.
We provide innovative solutions and premium operational services in intelligent manufacturing, digital supply chains, digital marketing and industrial IoT platforms.
Today, LINKWIN operates across industrial, commercial, agricultural and government sectors, serving over 300 customers in more than 50 countries and regions.
We focus on economic value, helping clients improve operational efficiency and drive sustainable growth.
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Business & Innovation
Intelligent Manufacturing
LINKWIN deeply understands clients’ demand for production line efficiency and enables production digitalization.
Through industrial vision, coding systems, OEE, lightweight MES, digital twin and digital dashboards, we help enterprises produce high-quality products while cutting costs and improving efficiency.
Highlights: Cloud Coding, Lightweight MES, LinkVision™ Vision Inspection
Digital Supply Chain
LINKWIN delivers customized solutions for full-chain traceability marketing, product anti-counterfeiting and smart warehousing, realizing end-to-end digital supply chain management with higher efficiency and transparency.
Highlights: Micro-Texture Code®, Full-Chain Traceability Solution
Digital Marketing
LINKWIN’s unique “code + data” driven omni-channel digital marketing helps brands connect with consumers precisely, build private traffic pools, enable personalized operations, boost sales conversion and enhance brand influence.
Highlights: Smart Mini Program Operation, Customized Omni-Channel Marketing Solutions
Industrial IoT Platform
LINKWIN deploys hybrid cloud services to provide dynamic, isolated IT resources for enterprises.
All data is secured by blockchain technology, supporting an annual increase of 30 billion product data entries and 200,000 IoT nodes.
Highlights: LinkIoT Cloud Platform, IIoT, Hybrid Cloud Services
