Industrial Inspection and Quality Control

Industrial inspection of an engine cylinder head with automated surface inspection by robot and 3D laser scanner for quality control in production.

Robust defect detection. Short cycle times. 100% inspection.

Requirements for component surfaces, whether for functional or purely aesthetic purposes, are increasing across various industries. At the same time, components are becoming more complex and variant diversity is rising.

Traditional manual surface inspections often reach their limits, particularly in the face of short cycle times, large components, and high production volumes.

Automated surface inspection systems enable reliable 100% inspection – a technology that PROFACTOR has been developing and successfully deploying for many years in fields such as automotive engine and gearbox production, aerospace, and the furniture industry.

This allows components to be fully checked within the line, enabling early defect detection and the corresponding optimization of upstream processes.

Surface Inspection and Measurement

Automated optical inspection of a wide range of materials.

Camera-based sensors are specifically tailored to your particular application, supporting both in-line control and stand-alone testing stations.
These optical systems ensure short cycle times while simultaneously providing high resolution and measurement accuracy.
By utilizing advanced image processing algorithms and AI, the system enables the reliable detection of defects and dimensions.

Visual Assistance for Component Testing

Where manual quality testing is irreplaceable, this technology makes the process significantly more reliable.

Camera-based sensors and AI-driven algorithms identify deviations on the component.
Employees receive relevant guidance projected directly onto the component, whether it is sitting at a workstation or moving along a conveyor belt.
These assistance systems reliably support employees, especially when dealing with complex components or high variant diversity.

Technologies

Advanced Optical Sensor Technology

Accurate inspection results require high-quality images. Depending on the application, industrial-grade line, matrix, or thermal cameras are used in combination with additional sensors.

For the reliable detection of three-dimensional defects or the measurement of fiber orientation, we utilize in-house developed camera-based sensors with integrated lighting.

Based on these technologies, customized sensor designs can be realized to meet specific inspection requirements such as scan speed, field of view, or working distance.

Automated Image Processing and Defect Evaluation

Defect detection and evaluation are based on complex image processing algorithms that go beyond simple image comparison by parameterizing and classifying individual features before matching them against defined defect limits.

Depending on the application, AI functions are utilized to improve flexibility for new defect characteristics.

Visual Assistance through Projection

In various scenarios where components must be individually final-inspected by employees, the process can be strenuous and tiring over long periods and with high variant diversity.

Projection systems utilize information from sensor-based inspection and visualize detected defects directly on the component, allowing employees to concentrate on the actual defects during the final inspection.

Complete Testing Systems

Automated industrial inspection systems are designed specifically for the given production environment and components. The system design, sensor selection, and handling systems are optimized regarding the requirements for inspection parameters and defect types.

For the inspection of curved components, inspection robots are used to guide the sensor precisely over the surface, enabling 100% inspection.

The inspection of complex components, such as gearbox housings, typically occurs in fully automatic inspection cells where several sensors and robots operate in parallel. PROFACTOR delivers inspection cells as turnkey systems or as complete inspection technology for integration into higher-level systems.

Solutions for Demanding Inspection Tasks

Developing the core technology in-house allows us to tailor solutions individually to meet specific customer requirements.

Industrielle Inspektion mit kamerabasierter optischer Oberflächenprüfung und Bauteilvermessung in der automatisierten Fertigung

Optical Surface Inspection and Component Measurement

Camera-based sensors with integrated lighting scan internal and external surfaces of components and detect even the smallest defects.

Specialized image processing software and AI algorithms parameterize and classify detected deviations, enabling a reliable OK/Not-OK decision.

In parallel with the surface inspection, contours and positions on components can also be measured.

Fully automatic inspection cells with multiple robots and sensors guarantee 100% inspection of complex components within very short cycle times.

Robotergestützte industrielle Oberflächeninspektion eines gekrümmten Bauteils mit optischem Sensorsystem

Surface Inspection of Fiber Composite Materials and Components

Camera-based sensors with integrated lighting scan the components and detect fiber orientation at the surface.

Specialized image processing software and AI algorithms, tailored to the material properties, classify detected deviations to ensure a reliable OK/Not-OK decision.

Special sensor designs enable automated in-line inspection throughout the entire manufacturing process, from the textile and pre-preg stage to the finished component.

Crack Inspection via Thermography

Thermal cameras record temperature distribution on the surface after the component has been thermally excited by sources such as lasers, flash lamps, or induction.

Characteristic sizes of cracks and other defects beneath the surface are calculated from the heat flow videos using image processing software and AI algorithms.

Thermography enables non-destructive, contactless, and fully automatic crack detection in continuous flow or paced production, and on robots.

Industrielle Inspektion mit visueller Assistenzsystem für die Bauteilprüfung und Endkontrolle mittels Kameras und KI-basierter Bildverarbeitung

Visual Assistance for Component Inspection and Final Control

Industrial cameras and AI-based image processing software recognize components and detect deviations from the target state.

Projection is used to generate and display context-specific guidance directly on the component or workstation.

Employees are relieved of stress, and complex inspection tasks can be performed faster, while full documentation of product and delivery quality is achieved simultaneously.

Industrielle Inspektion mit visueller Assistenz für die Qualitätskontrolle von Bauteilen am Fließband

Visual Assistance for Quality Control on the Conveyor Belt

Industrial cameras and sensors recognize the type and condition of components on the conveyor belt, even for lot size 1.

AI-based image processing software identifies deviations from the target state and calculates situational information, which is then projected precisely onto the moving components on the conveyor belt.

Operators on the line are relieved, and the inspection of highly variant components can be carried out faster and more reliably, including full documentation.

Added Value for Your Quality Strategy

Years of experience allow for tailored, reliable solutions for your inspection tasks in industrial quality assurance.

Robust sensors and software algorithms

ensure safe defect detection and a low pseudo-error rate.

Fully automatic 100% inspection with short cycle times

is achieved through robot-based multi-sensor systems.

The visualization of discovered defects at the conveyor or inspection station

via intelligent projection technology supports your employees.

We solve individual inspection tasks

through reliable technology and the delivery of turnkey inspection systems.

Application Areas

Selected real-world examples demonstrate the diverse applications of our inspection and assistance technology.

Industrielle Inspektion eines E-Antriebsgehäuses mit robotergestützter integrierter Oberflächenprüfung

Integrated surface inspection of electric drive housings

Industrielle Inspektion eines Roh-Gussteils mit automatisierter Oberflächenprüfung und bildbasierter Fehlererkennung

Automated surface inspection of raw castings

Industrielle Inspektion eines Faserverbund-Strukturbauteils aus der Luftfahrt mit robotergestützter optischer Bauteilprüfung

Component testing of aerostructures made of fiber composites

Automated fiber angle measurement using inspection robots

F-SCAN Wide Sensor zur großflächigen Materialprüfung von Carbon-Faser-Geweben

Large-area material testing of carbon fiber fabrics

Visual assistance for quality control in kitchen production

Video

Automatic surface inspection of electric drive housings

PROFACTOR, Your Technology Partner

From innovative ideas to industrial implementation

Requirements, Concept and Feasibility

After the initial exchange of information, we clarify objectives, components, and inspection tasks.

If needed, we test the basic feasibility of defect detection and cycle times using sample parts.

This creates a shared understanding of the inspection concept, along with a rough cost estimate as a basis for the following phases.

Specification, Quotation, and Engineering

Based on feasibility and your specifications, we prepare a detailed quotation.

We develop the solution, test the system in-house, and prepare it for delivery.

Commissioning and Service

After commissioning in your production environment, we validate system performance through acceptance tests, train your employees, and hand over the system for series operation.

Our service team is available to assist with questions regarding operation, maintenance tasks, adjustments due to altered component designs, system upgrades or the supply of spare parts, ensuring long-term system availability.

Proven Partnerships

Selected customers and partners from joint development and industrial projects.

Current Research Projects

Our technology portfolio is built on numerous research projects with national and international partners from industry, universities, and research institutions.

We combine practical requirements with global trends to develop forward-looking research initiatives. In this way, we work with our partners to ensure the competitiveness of industrial production.