Machine vision is a cornerstone of automation and industry 4.0. The global machine vision market is projected to grow at a compound annual growth rate (CAGR) of 5.90% from 2023 to 2030, reaching an estimated value of $17.89 billion by 2030. Companies adopting Industry 4.0 technologies, including machine vision, have reported gains of 10% to 12% in manufacturing output, factory utilisation, and labour productivity. We’ll focus on the key developments and highlight the implications for the future of automation here.

High-Resolution Cameras

Machine vision systems are increasingly integrated with high-resolution cameras for significant improvements of quality control. With resolutions exceeding 45 megapixels, these cameras can detect defects as small as 0.02 sq mm with an accuracy of 98% to 99.5% - a substantial improvement over manual inspection rates of 85-90%.

High-resolution cameras are transforming sectors such as automotive manufacturing and pharmaceuticals. They enhance automated vehicle inspections by identifying defects before vehicles leave the production line. In the pharmaceutical industry, they enable the precise inspection of oral solid dosage (OSD) forms and blister packs, ensuring the detection of issues such as chipped tablets, foreign objects, and empty pockets.

Event-Based Vision Sensors

The development of machine vision technologies continues with the integration of event-based sensors, which mimic the human optic nerve through the detection of changes in pixel brightness. These neuromorphic sensors enable real-time image capture and adaptive processing, functioning efficiently even in low-light environments while reducing redundant visual data.

Again, there are numerous examples of companies that have benefited from the integration of event-based vision technologies. For instance, Toyota have seen improvements of quality control and automation through the use of a deep learning vision solution from Accrovision. A major UK home-delivery business has also enhanced inventory management and order fulfilment through the integration of industrial Bluetooth scanners.

Enhanced AI Capabilities in Machine Vision

The development of AI and deep learning technologies is enabling improved image analysis and decision making. Manufacturers can rely on advanced vision systems for real-time feedback and adjustments to improve product quality. Connected with robotic technologies, vision systems allow for highly detailed inspection and the completion of tasks that would otherwise have to be carried out manually.

Quality is being greatly enhanced through AI and deep learning, with advanced imaging and machine learning algorithms allowing for the detection and classification of defects across various sectors. Such systems are also enabling the improved sorting of manufactured items in various shapes and sizes. For instance, a German bottle cap manufacturer has integrated a machine vision inspection system with the capacity to analyse up to 120 caps per minute for the identification of flaws in shape, material, and print quality.

3D & 4D Vision

The shift from 2D to 3D and 4D vision is unlocking new possibilities for automation and quality control. These advanced vision systems allow robots to interact with their environments more effectively and enhance quality control for products with intricate shapes and surfaces.

As John Keating, 3D Business Unit Manager for Cognex, said, “Until now, 3D has been too expensive and complicated to solve inspection applications for most customers”. This is changing, with the introduction of affordable technologies such as the 3D-L4000.  With the ability to place vision tools directly on a true 3D image of the part, users benefit from improved accuracy and potential to carry out different types of inspections.

Such benefits are also being realised through the integration of 4D vision for human-like powers of perception. These systems capture and convert 2D images into full 3D, with AI enabling the 4D-visualisation of elements such as shadows, edges, texture, and colour. This enables the faster and more precise picking placement of objects in warehouses. For instance, the integration of Sick’s Visionary-T Mini AP camera with the Nova 3D Presence Inspection sensorApp has improved the accuracy and efficiency of manufacturing tasks such as fill level monitoring and robot palletising.

Realise the Benefits with Automate UK & UKIVA

From high-resolution cameras to 4D processing systems, machine vision technologies have the potential to transform processes in the manufacturing sector. Speed, accuracy, and quality can all be improved through the integration of such advanced vision systems. Manufacturers stand to benefit through cost reduction, product line expansion, and increased customer satisfaction.

As the leading trade association for automation suppliers and technology end users, Automate UK is committed to the wider realisation of such benefits. Partnering with UKIVA, we will help companies to gain a competitive advantage and help businesses to thrive with machine vision technologies. Together, we’ll innovate the future of automation.