{"id":1125,"date":"2026-03-05T21:40:04","date_gmt":"2026-03-05T20:40:04","guid":{"rendered":"https:\/\/www.profactor.at\/?post_type=solution&p=1125"},"modified":"2026-05-29T08:44:22","modified_gmt":"2026-05-29T06:44:22","slug":"industrial-inspection-and-quality-control","status":"publish","type":"solution","link":"https:\/\/www.profactor.at\/en\/solution\/industrial-inspection-and-quality-control\/","title":{"rendered":"Industrial Inspection and Quality Control"},"content":{"rendered":"\n

Robust defect detection. Short cycle times. 100% inspection. <\/h3>\n\n\n\n

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. <\/p>\n\n\n\n

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

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.<\/p>\n\n\n\n

This allows components to be fully checked within the line, enabling early defect detection and the corresponding optimization of upstream processes.<\/p>\n\n\n

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Surface Inspection and Measurement<\/strong><\/p>\n

Automated optical inspection of a wide range of materials.<\/p>\n

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

    Visual Assistance for Component Testing<\/strong><\/p>\n

    Where manual quality testing is irreplaceable, this technology makes the process significantly more reliable.<\/p>\n

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    • Camera-based sensors and AI-driven algorithms identify deviations on the component.<\/li>\n
    • Employees receive relevant guidance projected directly onto the component, whether it is sitting at a workstation or moving along a conveyor belt.<\/li>\n
    • These assistance systems reliably support employees, especially when dealing with complex components or high variant diversity. <\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>\n\n
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      Technologies<\/h2>\n\n\n\n

      Advanced Optical Sensor Technology<\/h3>\n\n\n\n

      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. <\/p>\n\n\n\n

      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.<\/p>\n\n\n\n

      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.<\/p>\n\n\n\n

      Automated Image Processing and Defect Evaluation<\/h3>\n\n\n\n

      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.<\/p>\n\n\n\n

      Depending on the application, AI functions are utilized to improve flexibility for new defect characteristics.<\/p>\n\n\n\n

      Visual Assistance through Projection<\/h3>\n\n\n\n

      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. <\/p>\n\n\n\n

      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. <\/p>\n\n\n\n

      Complete Testing Systems<\/h3>\n\n\n\n

      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. <\/p>\n\n\n\n

      For the inspection of curved components, inspection robots are used to guide the sensor precisely over the surface, enabling 100% inspection.<\/p>\n\n\n\n

      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. <\/p>\n\n\n

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      Solutions for Demanding Inspection Tasks<\/h2>\n\n\n\n

      Developing the core technology in-house allows us to tailor solutions individually to meet specific customer requirements.<\/p>\n\n\n

      \"Industrielle<\/div>

      Optical Surface Inspection and Component Measurement<\/h3>

      Camera-based sensors with integrated lighting scan internal and external surfaces of components and detect even the smallest defects. <\/p>\n

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

      In parallel with the surface inspection, contours and positions on components can also be measured. <\/p>\n

      Fully automatic inspection cells with multiple robots and sensors guarantee 100% inspection of complex components within very short cycle times.<\/p>\n<\/p><\/div><\/div><\/div>\n\n

      \"Robotergest\u00fctzte<\/div>

      Surface Inspection of Fiber Composite Materials and Components<\/h3>

      Camera-based sensors with integrated lighting scan the components and detect fiber orientation at the surface.<\/p>\n

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

      Special sensor designs enable automated in-line inspection throughout the entire manufacturing process, from the textile and pre-preg stage to the finished component.<\/p>\n<\/p><\/div><\/div><\/div>\n\n

      \"\"<\/div>

      Crack Inspection via Thermography<\/h3>

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

      Characteristic sizes of cracks and other defects beneath the surface are calculated from the heat flow videos using image processing software and AI algorithms.<\/p>\n

      Thermography enables non-destructive, contactless, and fully automatic crack detection in continuous flow or paced production, and on robots.<\/p>\n<\/p><\/div><\/div><\/div>\n\n

      \"Industrielle<\/div>

      Visual Assistance for Component Inspection and Final Control<\/h3>

      Industrial cameras and AI-based image processing software recognize components and detect deviations from the target state.<\/p>\n

      Projection is used to generate and display context-specific guidance directly on the component or workstation.<\/p>\n

      Employees are relieved of stress, and complex inspection tasks can be performed faster, while full documentation of product and delivery quality is achieved simultaneously. <\/p>\n<\/p><\/div><\/div><\/div>\n\n

      \"Industrielle<\/div>

      Visual Assistance for Quality Control on the Conveyor Belt<\/h3>

      Industrial cameras and sensors recognize the type and condition of components on the conveyor belt, even for lot size 1.<\/p>\n

      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.<\/p>\n

      Operators on the line are relieved, and the inspection of highly variant components can be carried out faster and more reliably, including full documentation. <\/p>\n<\/p><\/div><\/div><\/div>\n\n

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      Added Value for Your Quality Strategy<\/h2>\n

      Years of experience allow for tailored, reliable solutions for your inspection tasks in industrial quality assurance.<\/p>\n

      Robust sensors and software algorithms <\/h3>
      ensure safe defect detection and a low pseudo-error rate.<\/div><\/div><\/div>

      Fully automatic 100% inspection with short cycle times<\/h3>
      is achieved through robot-based multi-sensor systems.<\/div><\/div><\/div>

      The visualization of discovered defects at the conveyor or inspection station<\/h3>
      via intelligent projection technology supports your employees.<\/div><\/div><\/div>

      We solve individual inspection tasks <\/h3>
      through reliable technology and the delivery of turnkey inspection systems.<\/div><\/div><\/div> <\/div>\n<\/div>\n\n
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      Application Areas<\/h2>\n\n\n\n

      Selected real-world examples demonstrate the diverse applications of our inspection and assistance technology.<\/p>\n\n\n

      \"Industrielle
      Integrated surface inspection of electric drive housings<\/div><\/div>
      \"Industrielle
      Automated surface inspection of raw castings <\/div><\/div>
      \"Industrielle
      Component testing of aerostructures made of fiber composites<\/div><\/div>
      \"Robotergest\u00fctzte
      Automated fiber angle measurement using inspection robots<\/div><\/div>
      \"F-SCAN
      Large-area material testing of carbon fiber fabrics<\/div><\/div>
      \"Industrielle
      Visual assistance for quality control in kitchen production<\/div><\/div><\/div><\/div>\n\n\n
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      Video<\/h2>\n
      Automatic surface inspection of electric drive housings<\/div>\n