How Cameras Are Used In Factories

Cameras have been important in high-quality manufacturing environments for decades. Now, however, they are growing into an essential part of quality and efficiency across many kinds of manufacturing processes. Let’s consider a few ways machine vision systems have been adopted into factories.

Ford Moves Forward on Camera Systems for Quality Control

In the automotive industry, where the modern assembly line made its debut, the integration of sophisticated computers into virtually every aspect of vehicle function has demanded companies adopt more comprehensive machine vision systems. Ford, which relied on manual inspections as recently as months ago, recently shifted to high-res cameras for some inspection tasks.

Ford’s dirt detection technology facilitates inspection of a completed motor vehicle after initial paintwork is done. All vehicles must undergo strenuous “touch up” process that eliminates flaws and imperfections: Now, instead of requiring personnel to view the chassis up close, a vision system examines more than 3,000 images to pinpoint problems. The Ford system uses 16 cameras to generate a complete 3D model of a vehicle.

Robotic Vision for Quality Assurance and Supply Chain

3D camera systems may be the way of the future, but both 2D and 3D systems are becoming more precise. Today’s cageless robots can use sensor arrays to self-orient on the manufacturing floor, locating needed parts on the X/Y axis and in rotation. These devices, formerly tethered to computers on the factory floor, now often have wireless capabilities.

Cameras have long been used to examine parts during picking, packing, and palletization. Now, however, they have become so powerful they can guide robots in 3D space to execute these tasks in real time. Machine vision systems that can recognize parts from any rotation during a high-speed assembly line process may soon be the norm in factories.

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Continuous Process Improvement With Advanced Cameras

Today’s manufacturing firms contend with global competition and work toward exacting quality control standards. To secure and maintain internationally recognized quality certifications – and the cost savings and efficiencies they unlock – more businesses are using cameras to determine how their machine tooling and floor setup could be better.

Cameras can verify correct orientation of parts, read barcodes or matrix codes, do dimensional measurements, check for defects, authenticate the diameter and shape of a hole, gasket, or bead, and communicate with a wide range of third party equipment. As bandwidth and storage capacity all increase rapidly, this last capability may be one of the most powerful.

Today’s camera modules are smaller than ever and are pushing boundaries in video encoding and compression that make them very versatile. Over time, it may be possible for camera-equipped robots to store and transmit production data in real time, ensuring its long-term storage. This will improve modularity and facilitate faster re-engineering of manufacturing processes.

Precise, high-speed vision systems are not yet universal in manufacturing, but underlying technology is rapidly expanding to meet demand. The manufacturing floor of tomorrow might well be the place to see cutting-edge machine vision hard at work meeting consumer and B2B needs.