Automating the Boroscopic Inspection Process for Precision and Consistency
In metal tube manufacturing, internal surface inspection is one of the most challenging quality control tasks. Traditionally, operators perform manual inspection using boroscopic cameras, sending them inside the tube to visually check for cracks, pits, corrosion, weld defects, or any other internal anomalies.
While this manual method can detect defects to some extent, it suffers from inconsistency, human error, and slow throughput—especially when hundreds of tubes must be inspected daily.
Intelgic brings automation, precision, and speed to this complex process with its AI-powered Metal Tube Inspection Automation System, a complete turnkey solution combining advanced optics, robotics, and machine vision intelligence.
The Challenge of Manual Boroscopic Inspection
In conventional inspection setups:
- Operators manually insert boroscopic cameras into metal tubes.
- The camera feed is visually observed on a screen to identify surface defects.
- Accuracy heavily depends on the operator’s experience and attention.
- Inspection time per tube is high, leading to bottlenecks in production.
Furthermore, inconsistent illumination, reflection from the inner walls, and camera misalignment often lead to missed defects or false detections. For small diameter tubes (5–10 mm) or tubes exceeding 2 m length, the challenge becomes even greater.
Intelgic’s Automated Metal Tube Inspection System
Intelgic has developed a comprehensive automation system designed specifically to inspect the inner walls of metallic tubes with high precision and repeatability. The system integrates robotic motion, specialized imaging optics, and AI-driven defect analysis, ensuring reliable detection of even micro-level imperfections.
1. Camera Insertion Mechanism
At the heart of Intelgic’s system lies an automated camera insertion module.
This module uses a robotic linear motion system to insert a high-resolution boroscopic or endoscopic camera inside the tube with controlled speed and alignment.
Key capabilities:
- Supports tube diameters as low as 5 mm.
- Can inspect tubes up to 2 meters in length with precise motion control.
- Motorized linear guide ensures smooth insertion and retraction.
- The movement and positioning are programmable through PLC-based or PC-based control systems.
- Integrated lighting ensures uniform illumination inside the reflective metal surface.
This eliminates human handling errors and maintains a consistent imaging path—critical for accurate AI analysis.
2. AI-Powered Image Processing and Defect Detection
Once the camera starts capturing images inside the tube, Intelgic’s AI-powered software comes into play.
The software is specially designed for metal tube inner wall inspection and is capable of identifying various surface defects such as:
Cracks or micro-cracks
Corrosion spots
Pitting
Weld discontinuities
Scratches and burrs
Deposits or foreign particles
Technical highlights:
- Works seamlessly with boroscopic cameras via USB interface.
- Real-time image acquisition and analysis.
- AI algorithms trained using domain-specific datasets for high accuracy.
- Adaptive illumination correction to handle reflections and lighting variation.
- Measurement and localization of defects with length and angular position.
- Integration with PLC or MES systems for automated feedback and traceability.
The system generates detailed inspection reports with defect maps, images, and metadata that can be used for quality certification and root-cause analysis.
3. Marking and Localization System
Intelgic’s solution doesn’t stop at detection—it also assists in physical identification of defect areas.
Through the Marking System, Intelgic automates defect localization on the tube’s outer wall.
Here’s how it works:
- Once the AI identifies a defect, it calculates the exact longitudinal position inside the tube.
- This positional data is transmitted to the marking module.
- A motorized marker or inkjet system marks the corresponding external location on the tube surface.
This enables operators or downstream processes (like cutting, repair, or rejection) to act precisely on the affected section.
Inspection for Long Tubes (Over 2 Meters)
For longer metal tubes—ranging up to 6 m or even 20 ft—creating a full mechanical insertion system becomes complex and cost-intensive.
In such cases, Intelgic provides a semi-automated inspection mode:
- Operators can insert the boroscopic camera manually in segments.
- Intelgic’s software processes the images section by section.
- The system provides defect mapping, image stitching, and reporting without requiring a full robotic insertion system.
This approach offers flexibility for larger or custom-length tubes while still leveraging Intelgic’s powerful AI inspection software.
System Integration and Customization
Intelgic’s metal tube inspection system can be deployed as:
- A standalone station for offline inspection, or
- Integrated into a production line for inline or near-line inspection.
The system architecture is modular, allowing customization for:
- Tube diameter and length ranges.
- Imaging device type (boroscopic, endoscopic, or area-scan camera).
- Lighting configurations (coaxial, ring, or directional LED).
- Reporting and database integration (SQL, NoSQL, or cloud dashboard).
Advantages of Intelgic's Automated Tube Inspection
100% Coverage
Complete visual coverage of the tube inner surface with consistent quality.
AI Precision
Detects micro-level defects invisible to the human eye with machine learning.
Time Savings
Reduces inspection time by up to 70% compared to manual methods.
Digital Reports
Generates detailed defect maps and quality reports for traceability.
Cost Reduction
Lowers labor costs and minimizes human error-related rework.
Flexible Integration
Works standalone or integrates with production lines and MES systems.
Applications
Intelgic’s Metal Tube Inspection Automation System is ideal for industries where internal surface integrity is critical, such as:
Automotive
Fuel injector tubes, brake lines
Aerospace
Hydraulic and pneumatic tubes
Energy
Heat exchanger tubes, boiler tubes
Medical
Surgical and catheter tubes
Metal fabrication
Metal fabrication and precision engineering
Manual boroscopic inspection is labor-intensive and subjective.
Intelgic’s AI-driven Metal Tube Inspection Automation brings a new era of speed, accuracy, and reliability to internal tube surface inspection.
By automating camera motion, enhancing imaging with specialized optics, and leveraging deep learning algorithms, Intelgic ensures that every tube leaving the factory meets the highest quality standards—with traceable, data-driven inspection reports.
