The most important first
In industrial image processing, the camera alone does not determine success. What matters is that the inspection task, process conditions and technology work together optimally. That is precisely what _ae VISION, the business unit of Aerne Engineering AG specialized in industrial image processing, is aimed at. Vision is used where image processing reliably improves a process – for example in pose recognition, metrology, surface inspection or OCR. Each solution is tailored to the specific application and its requirements. Simple tasks can sometimes be realized within a few weeks, while complex projects take correspondingly more time. What is crucial for a reliable Vision solution are clearly defined inspection features and a clean overall system design.
What we consistently see in practice: the challenge rarely lies with the camera alone. What matters is the interaction of a clearly defined inspection task, stable process conditions and clean integration into the overall process. Factors such as inspection features, illumination, part orientation, cycle time and environmental conditions can be as decisive as the hardware used. Only when these factors are aligned does a Vision solution emerge that reliably works in everyday industrial use.
For which applications are Vision solutions from Aerne Engineering AG suitable?
Aerne Engineering AG develops Vision and inspection systems for applications where optical recognition, measurement or inspection reliably supports or automates a process. Typical areas of application include pose recognition of components, metrology tasks, surface inspections or OCR applications. The focus is not on the single camera, but on the entire application. Each Vision solution is tailored to the concrete task, process conditions and the requirements of the overall process.
| Task | What the solution handles | When this is sensible |
|---|---|---|
| Pose recognition | Identify parts and determine their position and orientation | When parts are fed in at different positions or orientations |
| Metrology | Capture and inspect dimensions and geometric features without contact | When mass is to be controlled directly in the production or automation process |
| Surface recognition | Detect defined features and deviations on surfaces | When surfaces are automatically checked for defects or quality features |
| OCR reading | Automatically recognize and read characters, texts and codes | Product information, batches or markings are to be captured and checked automatically |
For a reliable Vision solution, the relevant inspection features must be clearly defined and reliably detectable under actual process conditions. The interplay of camera and software is not the only factor; lighting, part orientation, cycle time and environmental conditions also matter. The better these factors are coordinated, the more stable the inspection can be integrated into the overall process.
When is a Vision solution sensible – and when not?
A Vision solution is particularly sensible when relevant features can be reliably captured optically and the requirements of the inspection can be clearly defined. The decisive factor is not only the actual inspection task. Process conditions such as part orientation, illumination, cycle time, environmental conditions and integration into the overall process must also be considered. Not every task can be solved technically and economically sensibly with Vision. Therefore Aerne Engineering AG already at the beginning considers the entire application and checks which solution is suitable for the respective process.
“If we do not see a technically and economically sensible solution for a task, we communicate that openly and justify our assessment to the customer.”
When it is better not to start with Vision
If the inspection criteria are still unclear or the available image material is not clean enough, you should not jump straight into implementation. In such cases, Aerne Engineering AG first clarifies the task or refuses the project if no economically sensible solution is identifiable.
How does a Vision project with Aerne Engineering AG proceed?
Every Vision project starts with a clear understanding of the task, the process conditions and the desired result. On this basis, Aerne Engineering AG develops the appropriate solution concept. For complex or not yet sufficiently technically validated applications, a proof of concept can be used to test feasibility early. A typical project flow includes the following steps
- Define task and target image (requirements, inspection features, process conditions and interfaces are clarified together.)
- Create solution concept and offer (Based on the requirements, the technical solution is developed and offered.)
- Ensure feasibility if needed (For complex tasks, critical points are checked with a Proof of Concept.)
- Develop, build and test the system (The Vision solution is designed, programmed, built and tested under as realistic conditions as possible. The customer is regularly informed about project progress.)
- Perform FAT (Before delivery, the solution is tested and accepted with the customer in a Factory Acceptance Test (FAT).)
- Install and SAT at the customer (Subsequently the system is integrated on site and tested under real production conditions. The Site Acceptance Test (SAT) completes the process.)
Project duration strongly depends on the task and the scope of the solution. Simple Vision applications can be realized within a few weeks, while complex projects may take several months and in some cases up to a year. Factors include technical complexity, integration into the overall process and required development, testing and coordination effort.
What influences the costs of a Vision solution?
The costs of a Vision solution depend on the specific task and the requirements for the overall system. A flat-rate price is therefore not very informative. Key factors include the complexity of the inspection task, the required hardware and software, the integration into the existing process and the necessary engineering and testing effort.
| Cost driver | Impact on the solution |
|---|---|
| Complexity of the application | The more demanding the recognition or inspection, the higher the development, parameterization and test effort may be. |
| Camera, optics and lighting | Number and design of components depend on the inspection task, part and process conditions. |
| Software and analysis | Scope and complexity of inspection, analysis and documentation functions affect development effort. |
| Interfaces and data integration | Integration into controllers, higher-level systems or databases requires additional interfaces and coordination. |
| Mechanics and integration | Installation situation, protection concept and integration into the plant influence design and assembly effort. |
| Validation and tests | Depending on application and quality requirements, the effort for tests and validation of the solution may vary. |
A robust cost estimate is therefore only possible when the task, process conditions and requirements are sufficiently clarified. This way, not only the price but also the technical and economic benefits of the Vision solution can be assessed meaningfully.
How capable can an industrial Vision solution be?
The capability of a Vision solution depends on the respective application, the inspection requirements and the process conditions. That image processing can be used reliably even at very high production speeds is demonstrated by a concrete practical example from Aerne Engineering. In a OCR inspection line for cans, the applied characters and codes are automatically captured and checked during ongoing production.
The practical example shows that industrial image processing can be reliably integrated into a production process even at high throughput. The key is not only the speed of image processing. Camera, optics, illumination, software and process conditions must be tuned as a system to the specific application.
What is the difference to alternatives?
Not every inspection or measurement task must be solved with vision. The decisive factor is which technology works reliably under the given process conditions and is technically and economically sensible. Therefore Aerne Engineering AG considers the task holistically and includes potential alternatives in the solution finding. Vision is particularly suitable when features can be captured, inspected or measured optically without contact. Depending on the application, however, tactile measurement or another inspection method may be the more appropriate solution.
- Vision offers advantages when optical features can be captured without contact and multiple information can be evaluated simultaneously.
- Alternative inspection and measurement methods may be more sensible if they are more reliable, simpler or more economical for the concrete task.
- The key is the overall process: the right solution follows from inspection task, process conditions, required performance and cost-effectiveness.
The goal is not to deploy as much Vision technology as possible, but to develop the solution that fits the specific application best.
Frequently asked questions
What should be clarified before requesting a Vision solution?
When is a Proof of Concept sensible?
Why does Aerne Engineering AG not recommend a Vision solution for every inquiry?
How can one tell if Vision is suitable for an application?
What is crucial for a reliable Vision solution?
What matters for a successful Vision solution is not technology alone, but its interaction with the concrete task and the overall process. With _ae VISION, Aerne Engineering develops solutions where inspection requirements, process conditions, technology and economics are considered together from the start. This creates a Vision solution that not only works technically but is reliably integrated into the production process.
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Aerne Engineering AG, Arbon