A vision inspection system, also known as a machine vision system, is an automated inspection solution used for visual inspection and quality control during manufacturing. It combines cameras, optics, lighting, sensors, and software to capture, process, and analyze images or video of products, components, or materials. By analyzing this visual data in real time and at high speed, the system can detect defects, measure dimensions, and verify assembly quality according to the application's inspection requirements.
Cameras capture the images used for inspection. The number of cameras and their mounting positions depend on the surfaces that need to be examined. A simple part may require only top or bottom imaging, while more complex components may require side views, 360° imaging, or simultaneous inspection from multiple directions.
In addition to cameras, a vision inspection system can integrate other sensing devices, such as laser sensors or 3D scanners. Depending on the application, these sensors can be used for part-presence confirmation, position triggering, motion synchronization, material differentiation, and inspection of specific quality characteristics.
Clearly identifying a defect depends on more than camera resolution. Product material, color, surface condition, and defect type all affect how the imaging setup should be configured.
Appropriate lens, lighting angle, and illumination method affect how features such as dimensional edges, contours, cracks, burrs, scratches, and other inspection targets can be clearly distinguished in the captured image. For this reason, the imaging configuration is determined according to the actual sample and inspection requirements.
Vision software analyzes the images captured by the cameras and determines whether each part meets the predefined inspection criteria. Depending on the application, the software can perform dimensional measurement, contour inspection, position detection, completeness checks, surface defect detection, feature recognition, appearance inspection, and OK/NG (pass/fail) classification.
For appearance defects that are complex in form or difficult to define consistently using fixed inspection rules, an AI vision inspection configuration can also be used.
Reliable vision inspection also depends on how consistently each part reaches the camera’s inspection area. Since part shapes vary, the feeding, positioning, and support method needs to match the product being inspected.
For example, small parts such as screws, nuts, and washers can use a glass-dial inspection structure, while pins, rollers, and other cylindrical parts can use a U-groove dial. Headed fasteners can be handled with a rotary indexing dial, which carries each part through the required inspection stations in a defined position and orientation.
For this reason, an RKE vision inspection system includes more than cameras and software; it can also incorporate the automatic feeding, positioning, inspection, and sorting mechanisms required for the specific part.
Once inspection is complete, the vision software sends the result to the sorting mechanism. Accepted parts are directed to the OK collection area, while nonconforming parts are sent to the NG area.
This creates a continuous automated workflow:
Feeding → Inspection → Decision → Sorting
For applications that require fewer downstream manual handling steps, vision inspection, sorting, and packaging can also be integrated into one continuous system.
Vision inspection is not limited to surface defect detection. Depending on the part and its inspection requirements, RKE can combine dimensional, appearance, structural, and multi-surface checks within the same automated inspection process.
Vision inspection systems use captured product images to perform non-contact dimensional measurement. Depending on the part geometry, inspection items can include:
Selected RKE vision sorting systems can achieve an inspection accuracy of up to ±0.01 mm. Actual accuracy depends on factors such as part size, color, the features being inspected, and the vision system configuration.
By combining cameras with suitable illumination, the system can examine product surfaces and edge features for defects such as:
For parts with demanding appearance requirements or defects that are difficult to define using conventional inspection rules, an AI vision inspection solution can also be configured.
Beyond dimensions and surface quality, vision systems can also verify whether required structural features are present, absent, or correctly formed.
Depending on the product, inspection targets can include:
This type of inspection is particularly suited to screws, nuts, bolts, precision metal parts, and other industrial components with clearly defined structural features.
When defects occur on more than one surface, a single top view may not provide sufficient coverage. RKE can configure cameras in different directions based on the part shape and the surfaces that need inspection.
For parts requiring simultaneous inspection of multiple surfaces, a six-sided visual inspection machine can be used. For applications involving circumferential surfaces or internal and external defects, a 360-degree AI visual inspection machine can be configured.
Using multiple viewing directions helps reduce inspection blind spots resulting from reliance on a single camera angle.
Different parts call for different feeding and inspection structures. No single mechanical configuration works for every vision inspection application. Factors such as part shape, size, center of gravity, inspection surfaces, and production speed all affect equipment selection.
To accommodate these differences, RKE offers a range of vision inspection systems and optical sorting machines for different part inspection requirements.
The glass dial sorting and inspection machine is suitable for screws, nuts, washers, and a wide range of small precision parts.
The transparent glass dial allows cameras to capture images from different directions, making it suitable for combined inspection of dimensions, contours, and top and bottom surfaces. Selected configurations can achieve a sorting accuracy of up to ±0.01 mm.
The U-groove vision inspection system is designed primarily for automated inspection and sorting of cylindrical parts. Parts travel steadily along the U-shaped groove, allowing the cameras to capture images from consistent positions. Typical parts include pins, shafts, rollers, cylindrical precision components, and certain elongated metal parts. Selected configurations can achieve a sorting accuracy of up to ±0.01 mm.
For headed fasteners that require stable positioning during inspection, RKE offers a rotary indexing vision inspection system. Parts are presented in defined positions as they move through different inspection stations, allowing multiple visual inspection items to be configured as required. The system is suitable for bolts, screws, and other headed fasteners, including inspection of dimensions, structural features, and appearance.
For parts with circumferential surfaces or complex appearance criteria, a single 2D view might not cover all inspected areas. RKE’s 360° AI vision inspection system is designed for inspection of internal and external defects. Depending on the configuration, it can accommodate parts from 1–30 mm, achieve sorting accuracy of up to ±0.01 mm, and operate at 100–300 pcs/min.
RKE’s six-sided visual inspection system is engineered for precision parts that need to be examined across multiple surfaces. The system can be configured with six high-speed color cameras to capture images from different directions, supporting inspection of multi-sided appearance and structural features.
Not all quality features can be evaluated solely with cameras. For inspection needs covering appearance, dimensions, and material-related characteristics, vision inspection can be paired with eddy current testing. RKE’s integrated system combines optical inspection with eddy current testing to automatically inspect and sort applicable parts.
For applications that require automatic packaging after visual inspection, RKE can integrate inspection, sorting, and packaging into a single system. This integrated solution helps reduce post-inspection collection and manual transfer between processes. Selected configurations are suitable for products measuring 1–30 mm and can achieve inspection speeds of up to 200 pcs/min.
Suitable products include screws, bolts, nuts, rivets, washers, and other fasteners.
Depending on the application, the system can inspect dimensions, threads, heads, slots, hole positions, contours, and appearance defects.
RKE systems can inspect pins, shafts, rollers, turned parts, and other cylindrical precision components.
Typical inspection items include dimensions, contours, position, and surface quality.
For inspection of precision metal parts with complex structures or multiple surfaces, the system can be configured with the appropriate number of cameras, viewing angles, and feeding structure based on the part geometry and inspection requirements.
RKE vision inspection systems can be used for automated inspection of electronic and semiconductor-related parts, including capacitors, resistors, passive components, semiconductor chips, and other precision electronic components.
Inspection can cover part dimensions, position, appearance, structural integrity, and assembly features.
The vision inspection systems can inspect mobile phone parts such as screws, housings, and other components used in 3C digital products.
The systems can automatically check dimensions and appearance, including surface abnormalities such as scratches, gaps, depressions, and raised areas.
RKE vision inspection systems can be used for automotive fasteners and other high-volume precision components, providing automated inspection of dimensions and appearance. Parts that do not meet the preset inspection criteria are automatically separated from the production flow.
The vision inspection systems can inspect O-rings, seals, and other rubber and plastic components for inside and outside diameters, thickness, contours, missing material, burrs, and deformation.
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