Joining Quality
Ensuring Perfect Joints and Connections
Our cameras ensure the integrity and quality of critical joining processes like welding and soldering, crucial for safety and performance.
Key Applications
Welding Inspection (Automotive Body-side)
The OV20i vision system inspects welds for automotive suppliers, ensuring weld quality is up to par and completely replacing previous manual inspections that required significant labor. It addresses challenges faced by prior systems, such as downtime issues, false positives, and inconsistencies due to changing lighting conditions. With the OV20i, users can easily set up inspections for a high number of regions of interest (e.g., 135 welds), achieving reliable and precise results quickly, with the model working reliably within a week.
Safety Critical Welds Inspection
For a major automotive supplier, the OV20i addresses the struggle to consistently and accurately detect faulty safety critical welds, which previously relied on expensive manual inspections by 3P suppliers due to the variety of issues and high quality bar. With only 11 training images and 3 failure cases, Overview AI implemented a classifier algorithm to detect pass vs failed welds, achieving 100% accuracy across samples before production and significantly reducing costs.
Electronic Chip Soldering Defect Detection
A major electronic chip manufacturer utilized Overview AI to resolve issues with faulty chips leaving their lines due to minor soldering defects, which were difficult to identify visually and evaded existing systems due to glare and variability in defect location. The AI vision system was able to identify soldering defects with only a handful of images in multiple regions of interest. It also integrated with their PLC and built Node-Red logic to pause inspection lines and provide x-y coordinates of faults for easier identification and fixing.
Laser Soldering Inspection
Our vision system inspects laser soldering processes to ensure precise and reliable joints. Traditional solder inspection methods struggled with subtle defects such as tin balls, solder bridging, tin tips, solder deviation, low overlap, insufficient solder, and false welding — all of which can compromise product reliability and safety. By leveraging Overview AI's system, users can train models with only a small set of examples to robustly detect all common soldering issues, even under challenging conditions like glare and variable joint geometries. The system integrates seamlessly with existing line controls, providing real-time defect detection and precise localization, enabling immediate corrective action while reducing rework, improving quality, and preventing defective parts from reaching customers.