Machine Vision Controller with Live Vision Software for Comprehensive quality Inspection in manufacturing lines.
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In modern manufacturing environments, the need for precision, automation, and real-time monitoring is more critical than ever. Intelgic’s Machine Vision Controller, powered by our AI-driven software Live Vision, delivers an all-in-one solution for defect detection, measurement, and Standard Operating Procedure (SOP) monitoring. Our controllers are designed to seamlessly integrate with your production line, offering high performance and scalability, whether you’re measuring dimensions, inspecting for defects, or ensuring SOP compliance.
A machine vision controller is the central unit that processes images and data captured by imaging devices (cameras, sensors, etc.) in a manufacturing environment. It connects to multiple imaging devices and analyzes the incoming data using advanced AI algorithms. Intelgic’s controllers come preloaded with our proprietary Live Vision software, which enables real-time analysis and decision-making for a wide variety of manufacturing applications.
AI-Driven Machine Vision Software: Live Vision At the heart of our controller is Live Vision, a powerful AI-driven software designed for defect detection, precision measurement, and SOP monitoring. Live Vision processes data in real time, providing immediate insights and feedback for both automated and manual interventions. The software is highly adaptable, capable of handling multiple applications across industries.
Our controller is designed to easily integrate with Programmable Logic Controllers (PLC) and Supervisory Control and Data Acquisition (SCADA) systems, allowing for streamlined communication within your factory’s automation infrastructure. This ensures that the data generated by the machine vision system is accessible to other control systems for further action, such as halting production lines, initiating corrective actions, or alerting operators.
Intelgic’s machine vision controller is capable of connecting to more than one imaging device or camera. This enables simultaneous inspection from multiple angles, increasing the accuracy of defect detection and measurement. The controller can handle inputs from devices located up to 100 meters away, offering great flexibility in placing cameras in optimal positions while housing the controller in a secure, central location.
Every production environment is unique, and our controllers are fully customizable to meet the demands of your specific applications. Whether you're inspecting delicate electronics for micro-defects or monitoring large machinery for dimensional accuracy, we tailor both the hardware and software to fit your requirements. Live Vision is optimized for the selected use case, ensuring accurate results and comprehensive insights.
With Live Vision, our controllers are capable of real-time defect detection, offering instant identification of defects such as scratches, dents, misalignments, or missing components. The system alerts operators or triggers automated actions the moment a defect is detected, reducing waste and increasing production efficiency.
Our controller doesn’t just stop at defect detection—it can also monitor adherence to Standard Operating Procedures (SOPs) by analyzing real-time video streams to ensure that workers and machines follow set protocols. This is especially valuable in industries with strict compliance standards such as pharmaceuticals, food production, and automotive manufacturing.
The controller can be placed 20 to 100 meters away from the imaging devices, allowing it to be housed in a dedicated control room or server location while the cameras and sensors are positioned on the production floor. This offers greater flexibility in system layout and ensures that the controller is located in a secure environment.
Whether you’re running a small-scale production line or a massive factory with hundreds of cameras, Intelgic’s machine vision controller is built to scale. Our systems are designed to handle high-volume data processing while maintaining rapid response times. As your production grows, the system can easily expand by connecting additional cameras or upgrading the controller’s processing power.
Multiple cameras or sensors are positioned at critical points along the production line, capturing high-resolution images or video streams. These imaging devices are connected to the Intelgic machine vision controller via robust, industrial-grade connections, ensuring stable and reliable data transmission over long distances.
The controller processes the incoming data in real time using Live Vision, which applies AI algorithms to analyze each image or video frame. The software identifies critical dimensions, detects defects, and checks for SOP adherence, providing instant results without interrupting production.
The controller is connected to the plant’s PLC or SCADA system, enabling seamless communication between the vision system and other control systems. This allows the machine vision controller to trigger actions based on its findings—such as halting production, sending alerts, or adjusting machinery settings.
The system generates real-time reports, showing detailed insights into measurements, defect trends, and SOP compliance. Operators can access this information via dashboards or receive alerts when issues are detected, ensuring quick corrective actions.
Based on the specific needs of your production line, Intelgic works with you to fine-tune both the controller hardware and the Live Vision software. This ensures that the system delivers optimal performance for your use case, whether you need ultra-high precision measurements or rapid defect detection in fast-moving parts.
Inspect metal parts such as tubes, rods, sheets, and castings for defects, including surface imperfections, dents, or misalignments. The system measures critical dimensions like thickness, diameter, and straightness, ensuring that metal parts meet industry standards for quality and precision. The contact-less measurement ensures no damage to polished or finished surfaces, making it ideal for inspecting critical components in metal fabrication.
Detect defects in engine components, body panels, and assemblies. Monitor dimensions of critical parts such as gears, shafts, and brake discs in real-time, ensuring they meet stringent safety and quality standards.
Inspect turbine blades, fuselage panels, and other high-precision components for defects and dimensional accuracy. Monitor compliance with SOPs during critical assembly processes.
Measure and inspect printed circuit boards (PCBs), connectors, and microchips for defects, ensuring that each component is correctly placed and soldered. Monitor assembly lines for consistent SOP adherence.
Ensure packaging integrity and quality by detecting defects such as misalignment, incorrect labeling, or damaged containers. Monitor SOP compliance in environments where cleanliness, safety, and accuracy are paramount.
Measure the dimensions of plastic parts, rubber seals, and containers in real-time, detecting any deformation, inconsistencies, or defects. The system ensures that even flexible materials are measured accurately.
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