Danube Dynamics and Aspöck Systems have introduced an automated solution for intricate lamp inspections, leveraging adaptive AI and IDS industrial cameras to ensure precision, adaptability, and comprehensive traceability in real-world production settings.
As production companies face increasing demands for diverse variants, shorter delivery windows, and unyielding quality expectations, traditional visual checks can often fall short.
Visual quality control is among the foremost challenges for modern manufacturing due to the costs incurred by production errors, which affect both finances and company reputation. To manage variant diversity and uphold high standards, AI-supported image processing is becoming a vital tool for automating inspections.
Austrian company Danube Dynamics, in collaboration with Aspöck Systems, demonstrates how complex end-of-line testing of multi-chamber lamps can be automated using the AI solution “auros for quality”, alongside IDS camera technology, adding instant value across diverse production environments.
Aspöck Systems specialises in manufacturing multi-chamber vehicle lamps, requiring thorough testing at the production line’s end. Beyond simple functionality, ensuring the correct chamber is activated is crucial, as any mistake—such as an incorrect signal triggering another function—can have serious repercussions.
This must be achieved amid typical production challenges such as component alignment, ambient light interference, dust, dirt, and a multitude of variants. Traditional fixed-rule systems often struggle with such complexities, necessitating significant adjustments for each product change and presenting difficulties in reliably detecting unexpected error patterns.
Aspöck Systems utilises Danube Dynamics’ “auros for quality” system, centred on adaptive AI processing image data on an industrial PC (IPC) in real time, paired with two IDS uEye XCP series cameras.
“Our solution operates with adaptive algorithms rather than fixed testing rules, enabling reliable identification of complex or unforeseen error patterns while quickly adjusting to new products,” explains Nico Teringl, CEO of Danube Dynamics. IDS was chosen for its optimal interface, price, size, and advisory support. “Together, we found a camera that precisely meets our needs, ensuring lasting precision,” Teringl elaborates.
The IDS U3-3680XCP Rev.1.2 camera features a 5.04 MP rolling shutter CMOS sensor, consistently delivering detailed, low-noise images under challenging lighting conditions. Back Side Illumination technology enhances sensitivity and reduces noise, providing advantages in low light or dusty environments.
“The compact, robust design and superior low-light performance make this model ideal for demanding inspections,” emphasises Jürgen Hejna, Product Owner 2D Cameras at IDS. Additionally, the IDS peak software streamlines camera integration, significantly reducing setup times. “Thanks to IDS peak, we rapidly deployed and integrated the solution into Aspöck’s existing production environment,” adds Teringl.
In active use, the system enables individual lamp chambers through a control system. Two identical IDS cameras capture and evaluate images concurrently on the IPC using AI, allowing parallel processing to enhance cycle time and efficiency. Local data processing eliminates cloud reliance, preserving data sovereignty and reducing latency, vital for preventing production downtime at Aspöck Systems. The solution adapts to lamp alignment and withstands environmental variations such as light and contamination changes.
Real-time results display on an HMI touchscreen, are automatically logged, and can be communicated to a higher-level production system via an API. This creates a closed inspection loop, replacing manual checks and ensuring comprehensive traceability.
Combining “auros for quality” with IDS camera technology elevates Aspöck Systems’ inspection capabilities, detecting errors reliably even under adverse conditions.
