Danube Dynamics and Aspöck Systems have collaborated to automate the inspection of complex lamps using adaptive artificial intelligence (AI) and IDS industrial cameras, ensuring precision, adaptability, and traceability in real production settings.
Manufacturing firms face considerable pressure today as they navigate increasing variant demands, contracting delivery timelines, and the need to maintain low error rates, all challenges that traditional visual inspections struggle to meet.
AI in Visual Quality Control
Visual quality control presents a significant challenge to the manufacturing industry due to the high costs associated with production errors. AI-driven image processing is emerging as an essential technology for automating inspections, managing diverse product variants efficiently, and maintaining top-tier quality.
This is illustrated by the Austrian firm Danube Dynamics, alongside Aspöck Systems, in their quest to automate end-of-line testing for multi-chamber lamps. Their integration of the AI solution "auros for quality" with IDS camera technology enables the effective handling of complicated inspection tasks across varied production environments, providing clear advantages for businesses of any size.
Beyond Simple Lighting Tests
Not only is it critical to verify lamp illumination, but also to ensure the correct operation of its chambers
Aspöck Systems, a producer of multi-chamber vehicle lamps, must perform reliable tests at the conclusion of production processes. Not only is it critical to verify lamp illumination, but also to ensure the correct operation of its chambers.
Misalignments, such as a flashing signal inadvertently triggering the rear fog light, could lead to significant road safety issues. Furthermore, typical production factors like varied component orientations and environmental interferences create hurdles that traditional systems, which rely on fixed test rules, often cannot overcome. Changing products necessitates laborious adjustments, and unexpected error patterns are challenging to identify.
Seamless AI and Camera Integration
To address these challenges, Aspöck Systems has implemented the "auros for quality" solution by Danube Dynamics. This solution employs adaptive AI algorithms that analyze image data in real-time via a robust industrial PC on the production line. Key to this integration are two industrial cameras from IDS's uEye XCP series.
"Our solution avoids rigid testing rules in favor of adaptive algorithms, allowing us to reliably detect even complex or unforeseen error patterns and swiftly adjust systems to new products," explains Nico Teringl, CEO of Danube Dynamics. The strategic choice of IDS was influenced by several factors including interface compatibility, cost efficiency, and camera dimensions. Teringl further notes, "The support from IDS was crucial in aligning the camera choice with our precision requirements."
Adaptation to Adverse Conditions
The IDS U3-3680XCP Rev.1.2 camera efficiently uses a 5.04 MP rolling shutter CMOS sensor to deliver detailed images with minimal noise, even under challenging conditions like dim lighting. The Back Side Illumination technology enhances its sensitivity and noise performance, advantageous amidst low light and contaminants.
"The compact size, durable design, and excellent low-light capabilities of this model make it ideal for robust end-of-line inspections," notes Jürgen Hejna, Product Owner 2D Cameras at IDS. Moreover, the IDS peak software environment aids in camera connectivity, simplifying system integration and operation within Aspöck's existing production context, as emphasized by Teringl.
Streamlined and Efficient Operations
During operational processes, multi-chamber lamps are tested sequentially by a control system
During operational processes, multi-chamber lamps are tested sequentially by a control system, with two identical IDS cameras capturing images for AI evaluation on an IPC. This parallel operation method optimizes cycle times and boosts process efficiency.
One notable advantage is the localized processing which excludes cloud dependency, ensuring data integrity, reliability, and low latency—critical factors for Aspöck Systems to avoid production halts. This system, resilient to issues like component misalignment and environmental interferences, allows for real-time results display, automatic logging, and seamless API-driven transmission to a higher-level production system. This comprehensive inspection protocol effectively replaces manual inspections while maintaining traceability.
Enhanced Inspection Capabilities
By integrating "auros for quality" with IDS camera technology, Aspöck Systems has significantly improved their end-of-line inspection processes.
The technology reliably identifies errors under adverse production conditions and can swiftly adapt to new product variants via a user-friendly touchscreen interface, negating the need for extensive programming. This technology also provides detailed visualizations and documentation of inspection results, as highlighted by Teringl, "The support from IDS not only helped us select the right camera but also tailored the solution to our specific needs."
The Future of Quality Assurance
With increasing demands in the automotive sector for complex inspection tasks and heightened accuracy, advanced cameras paired with AI-driven analysis are quickly becoming essential.
"There's a clear movement towards intelligent, AI-supported image processing systems versatile enough to adapt to new products and processes with minimal effort," notes Teringl. This demand underscores the development of "auros for quality," designed in concert with IDS camera technology. The uEye XCP series, noted for its compact housing and C-mount, stands out in this advancing field.
Danube Dynamics and Aspöck Systems automate complex lamp inspections using adaptive AI and IDS industrial cameras to ensure accuracy, flexibility, and full traceability under real production conditions.
Production companies are under enormous pressure today: Customers are demanding more and more variants, delivery times are shrinking, error rates must not increase, and traditional visual inspections quickly reach their limits.
AI-supported image processing
Visual quality control is becoming one of the biggest challenges for the manufacturing industry. Every production error costs time, money and reputation. AI-supported image processing is therefore becoming an indispensable tool for automating inspection processes, efficiently managing variant diversity and ensuring the highest level of quality.
The Austrian company Danube Dynamics, together with Aspöck Systems, demonstrates how end-of-line testing of multi-chamber lamps can be efficiently automated. The combination of the AI solution "auros for quality" and IDS camera technology allows even complex inspection tasks in diverse production environments to be reliably mastered – a solution that offers immediate added value for companies of all sizes.
Background: More than just "light on, light off"
Aspöck Systems manufactures multi-chamber lamps for vehicles, which must be reliably tested at the end of the production line. It is not only important whether a lamp lights up, but also whether the correct chamber is enabled.
A flashing signal must not accidentally activate the rear fog light – a mistake that could have serious consequences on the road. Added to this are typical production conditions: different orientations of components, extraneous light in the hall, dust and dirt, and a wide variety of variants. Traditional systems based on fixed test rules reach their limits here. Every product change involves a great deal of adjustment work, and unexpected error patterns are difficult to detect reliably.
Solution: AI and camera working together
To overcome these hurdles, Aspöck Systems relies on the "auros for quality" solution from Danube Dynamics. At its heart is an adaptive AI that processes image data in real time on a powerful industrial PC (IPC) directly on the line. Image capture is handled by two industrial cameras from the uEye XCP series by IDS.
“Our solution does not work with rigid testing rules, but with adaptive algorithms. This enables us to reliably identify even complex or unexpected error patterns and adapt systems to new products very quickly," explains Nico Teringl, CEO of Danube Dynamics. The decision to go with IDS was a conscious one: "In addition to the interface, price and size, the advice provided by IDS was the decisive factor for us. Together, we found the camera that exactly meets our requirements and guarantees the required precision on a permanent basis," says Nico Teringl.
Challenging lighting conditions
The IDS U3-3680XCP Rev.1.2 used features the 5.04 MP rolling shutter CMOS sensor onsemi AR0521 and consistently delivers detailed, low-noise images, even in challenging lighting conditions. Back Side Illumination technology ensures high sensitivity and low noise levels, offering a clear advantage in low ambient light or dirty conditions.
"The combination of compact size, robust design and superior low-light performance makes this model the ideal component for demanding end-of-line inspections," emphasises Jürgen Hejna, Product Owner 2D Cameras at IDS. In addition, the IDS peak software environment facilitates the connection of cameras and significantly reduces the integration effort. "Thanks to IDS peak, we were able to get the solution up and running very quickly and integrate it swiftly into the existing production environment at Aspöck," adds Nico Teringl.
Higher-level production system
During operation, the multi-chamber lamps are enabled individually by a control system. Two identical IDS cameras capture the images, which are then evaluated on the IPC using AI. The two cameras operate in parallel: While one product is being tested, the next product can already be placed on the test bench.
This parallel approach increases cycle time and boosts efficiency. A key advantage of the solution is local processing without the cloud: This guarantees full data sovereignty, high reliability and minimal latency which is a crucial factor for Aspöck Systems, where production downtime must be avoided at all costs. The solution is independent of the exact alignment of the lamps and robust against environmental variables such as extraneous light or contamination.
The results are displayed in real time on an HMI touchscreen, automatically logged and can be transmitted to the higher-level production system via an API. This creates a closed inspection process that replaces or effectively supplements manual visual inspections while also ensuring complete traceability.
Result: Efficient, flexible, reliable
By combining "auros for quality" with IDS camera technology, Aspöck Systems has taken its end-of-line inspection to a whole new level. Errors are reliably detected under even the most adverse production conditions. The system can be adapted to new product variants in just a few minutes via the touchscreen, without the need for time-consuming programming. At the same time, those responsible benefit from clear visualization and digital documentation of the results.
“The support provided by IDS was a decisive factor in our success. Not only did they provide us with the right camera, they also advised us on how to tailor the solution to our requirements,” summarises Nico Teringl.
Outlook: Quality assurance in transition
Quality control requirements in the automotive sector continue to increase. Inspection tasks are becoming more complex, the required accuracy is increasing, and powerful cameras with AI-supported evaluation are becoming indispensable.
“We are seeing a clear trend towards intelligent, AI-supported image processing that is flexible enough to respond to new products and processes without requiring a great deal of effort. That is exactly why we developed 'auros for quality' in combination with IDS camera technology," says Teringl. Product - uEye XCP - The industry's smallest housing camera with C-mount.
