Optical Inspection System of the Operating Line

The system is designed for visual quality control at different stages of the technological cycle of product manufacturing.

The need for the operator to monitor the quality of product manufacturing is completely eliminated

Reducing defects by 99%

Download the presentation

Architecture

The result of the work of SOKOL

Instant detection of defects

Reduction of defects and downtime

Stable product quality

Increased line productivity

24/7 monitoring without interruptions

Interaction scheme

Advantages

Complete control without human intervention

The system continuously monitors product quality in real time and instantly responds to deviations – without an operator or human error.

Optical accuracy up to microns

The high resolution of the cameras (up to 30 MP) allows us to capture the smallest defects, invisible to the eye, ensuring consistent quality at every meter of the line.

Intelligent analytics and notifications

The SOKOL software package doesn't just record defects, it analyzes the causes and sends signals to SCADA, MES, Telegram, or SMS, preventing recurrence of errors.

A reliable domestic platform

A Russian-made controller with a minimum of imported components and full compliance with the requirements for domestic electronic equipment and software.

Versatility of application

Suitable for incoming, operational, and outgoing inspection—one system covers all visual quality control tasks

Easy integration with factory systems

OPC DA/UA compatibility and direct data exchange with MES and ERP systems provide a unified digital environment

Reducing costs and defects

Automatic analysis prevents the release of low-quality products and reduces the loss of raw materials, energy and time.

High performance

Work at speeds up to 100 m/min with multi-threaded data processing – control keeps up with the line

Guaranteed support and development

Integration with enterprise equipment and systems

Transfer of control signals and data to SCADA, MES, ERP, Telegram, SMS, OPC

Statistics and reporting

Generate reports by batch, line, shift, and defect type for process analysis and optimization

Integration and further training of the system

Возможность дообучения нейронной сети на новых типах дефектов

System capabilities

Optical surface inspection

Automatic detection of defects - scratches, bubbles, dirt, cracks and uneven coating

Control of geometric parameters

Measuring diameter, ovality, layer thickness, tape width, gaps and offsets of elements

Analysis of uniformity of material application

Monitoring the uniformity of talc coating, painting, insulation, varnishing, and coating

Color and shade control

Detection of deviations from the standard color, fading, or overexposure of the coating, which is important for cables, pipes, packaging, etc.

Control of markings and inscriptions

Text, barcode and marking recognition – checking readability, position accuracy and contrast

Control of product shape and assembly

Determination of distortions, displacements, incorrect positions of layers or components of the structure

Temperature and spectral analysis (optional)

Infrared control of surface heating or temperature distribution during extrusion and cooling

3D visualization of the product (optional)

Accurate reconstruction of the shape and geometry of a product in real time using laser scanners allows for the detection of hidden defects and deviations that are inaccessible with conventional 2D inspection.

X-ray examination of the internal structure (optional)

Allows you to see what is hidden from the camera: control the integrity of the wires, the presence of inclusions, voids, delamination and defects inside the product

Minimum defect size

from 0.5 mm

up to 100 m/min

Speed in standard configuration

Any kind of control

Input control

The system checks the quality of incoming raw materials and auxiliary materials before they enter production, recording defects, contamination, and inconsistencies in geometry or surface structure.
Continuous monitoring of supplied raw materials allows us to influence the quality of suppliers' products and eliminate defective batches.

Opetational control

During or between process operations, the system monitors compliance with process parameters: coating presence, uniformity of material application, and product geometry.
Deviations are immediately detected, and the operator receives an alarm or control action on the equipment for automatic correction.

Output control

At the final stage of production, the system analyzes the appearance, packaging, labeling, and compliance with storage standards of finished products.
This ensures that only fully compliant products reach the warehouse and the customer.