In a nutshell!

A leading metal parts manufacturer needed a breakthrough in quality control. Their production line required near-perfect precision to meet the demands of automotive and aerospace clients. With tolerances as tight as ±0.01 mm and production speeds exceeding 120 parts per minute, even the slightest defect could compromise functionality or safety. To ensure every part met these stringent standards, they turned to CTRL Engineering for a cutting-edge machine vision solution.

machine vision

“We’ve developed a machine vision system that ensures each metal part meets the highest quality standards, setting new benchmarks in the industry. 📷⚙️”

Aaron Wittouck – Development Engineer at CTRL Engineering

Quality Challenges in High-Speed Metal Parts Production

Maintaining precision in a high-speed manufacturing environment presented unique challenges:

  • Stringent tolerances: Ensuring dimensions within ±0.01 mm required reliable, high-resolution inspection tools.
  • Speed of inspection: Parts moving at over two per second demanded real-time processing capabilities.
  • Detection of micro-defects: Identifying scratches, dents, or misalignments invisible to the naked eye.
  • Scalable system: Flexible integration into existing production lines without slowing output.

Synchronized Machine Vision and Motion to the Rescue!

CTRL Engineering delivered a fully integrated vision system that addressed these challenges. Key features included:
  • High-resolution cameras: State-of-the-art cameras captured even the smallest surface defects, ensuring tolerances were consistently met.
  • Advanced image processing: Real-time algorithms identified defects in milliseconds, enabling immediate action on faulty parts.
  • Custom lighting system: Optimized illumination enhanced visibility of critical features, improving defect detection rates.
  • Seamless line integration: The system interfaced with existing machinery, maintaining high throughput without compromise.
  • Automated decision-making: Faulty parts were automatically diverted, minimizing human error and maximizing productivity.

Digital Transformation keeps production in Belgium

The machine vision system revolutionized the manufacturer’s quality assurance process:

  • Near-zero defects: Defective parts were reduced to less than 0.01%, exceeding client requirements.
  • Increased throughput: Real-time inspection maintained production speeds above 120 parts per minute.
  • Actionable insights: Analytics provided detailed reports on defect types and frequency, guiding process improvements.
  • Cost savings: Reduced rework and scrap rates significantly lowered operational costs.

This implementation positioned the manufacturer as a trusted supplier to high-stakes industries, enhancing their reputation for quality and reliability.

Why it matters to you?

For manufacturers striving to deliver flawless products at scale, precision is non-negotiable. CTRL Engineering provides tailored solutions that combine advanced machine vision with seamless integration to enhance quality and efficiency.

What we offer:

  • Expertise in real-time inspection systems
  • Solutions designed for high-speed manufacturing environments
  • Proven track record of enhancing production quality

If precision and reliability are critical to your production line, contact CTRL Engineering today. Let’s ensure every piece you produce meets the highest standards.

 

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