IDS Imaging Development Systems GmbH - Experts & Thought Leaders

Strong reflections, changing light conditions, or large brightness differences complicate many applications ofindustrial image processing. High Dynamic Range (HDR) extends the measurable dynamic range and reveals details that may be lost in overexposed or underexposed areas of an image. Since different applications have different requirements, choosing the appropriate HDR method is an important step. Depending on the application, the focus may be on dynamic range, resolution or motion tolerance. Combining softwares Accordingly, IDS Imaging Development Systems GmbH combines various HDR technologies within a singlesoftware environment. This allows users to compare, test, and integrate the respective features into theirapplications more easily. With Clear HDR, Quad HDR, and Sequence HDR, IDS supports three HDR modes for different requirements regarding dynamic range, resolution, and motion. HDR-capable IDS cameras can be configured, output data captured, and HDR results processed and visualised via IDS peak. Authority comment "Users want to use HDR and not develop HDR," says Heiko Seitz, Product Marketing Manager at IDSImaging Development Systems. "That is why we combine various HDR technologies as end-to-end Softwaresupport from capture to the finished HDR result in IDS peak. This simplifies evaluation, reduces integrationeffort, and accelerates the path to the right solution." Integration of softwares HDR is more than just a function of the image sensor. Only the interaction of the sensor and the camerafirmware with the image processing on the PC makes the additional image information practically usable.That is why IDS integrates central functions such as camera acquisition control, various image data formats,as well as the merging of HDR sensor data and tone mapping algorithms directly into the IDS peak SDK. Users thus gain access to individual HDR exposures as well as to calculated HDR and LDR results. The IDSpeak Cockpit allows users to explore and test the entire HDR toolchain and to visualise the resulting HDRimages. All of this is possible without prior programming. Source code samples further simplify integrationinto users' own applications. Numerous industrial image processing applications benefit from this approach. These include quality controlof reflective components, logistics and OCR applications, robotics and automation, welding processes, aswell as traffic and outdoor applications. In medical technology and microscopy, too, HDR can be used tomake more image information from high-contrast scenes usable.

Dust, moisture and high-pressure cleaning place high demands on cameras used for industrial process monitoring. With the new uEye SFA, IDS Imaging Development Systems GmbH is expanding its uEye Live monitoring range with an especially robust model designed for challenging operating conditions. The camera combines an IP69K-rated housing and high image quality with flexible streaming functions. The uEye SFA has been developed for applications that require reliable live images, even in harsh environments. Its housing protects against dust ingress and withstands high-pressure water jets during cleaning processes. Flexible streaming functions Screw-lock connectors provide additional operational reliability. Thanks to Power over Ethernet (PoE), both data and power are transmitted via a single cable over distances of up to 100 metres. "With the uEye SFA, we offer users a rugged monitoring camera that is easy to integrate and delivers reliable live images even under demanding conditions," explains Marcus Rembold, Product Manager at IDS. "Its 8-megapixel IMX678 sensor from Sony's STARVIS 2 series ensures excellent image quality, even in low light environments." Like all models in the series, the uEye SFA is designed for standalone operation. It supports video streaming, hardware-accelerated encoding, and event-based recording. Multiple streams can be configured and operated in parallel, providing additional flexibility when different stream settings are required for process monitoring. The uEye Live family also includes the compact uEye SCP, featuring the industrial standard format of 29 x 29 x 29 mm, and the uEye SLE, a space-saving single-board camera measuring just 45 x 45 mm. IDS therefore offers a range of camera designs for flexible live monitoring applications in industrial processes

Metallic, highly reflective surfaces are among the most challenging objects to inspect in machine vision applications. Reflections obscure details, defects often only become apparent from certain angles, and the quality of manual visual inspections varies throughout the working day. The Austrian company Danube Dynamics, in collaboration with EVVA, a manufacturer of mechatronic access solutions, demonstrates how these challenges can be managed with an AI-supported testing system. The system captures components placed in an orderly manner in a box in one step, automatically assesses surface defects, and integrates quality control reproducibly into the production process. Strict quality specifications Background: Challenging surfaces, high requirements - At EVVA, metallic components undergo several process steps and must meet strict quality specifications. These include, among others, locking cylinders, cylinder cores, and other finely machined or galvanised precision parts from access technology. Mechanical defects such as scratches under 0.1 mm and galvanisation errors must be detected – deficiencies that are often hardly visible to the naked eye. The central difficulty: Highly reflective surfaces reflect light and may conceal relevant features. For a reliable assessment, multiple viewpoints are often necessary. In practice, this complicates maintaining a consistently high quality of manual inspections. A solution was sought that reliably detects defects, supports employees, and integrates stably into the production process. Mechanical locking cylinder with a high-precision metal surface – test object of the AI inspection. Solution: Closed test box, coordinated lighting, AI To reliably solve these challenging inspection tasks, an AI-powered inspection system was developed in collaboration with Danube Dynamics. AI-powered inspection system The system captures components arranged in a 400 × 300 mm Eurobox in one step, automatically assesses surface defects, and integrates quality control reproducibly into the production process. Up to 126 components are arranged in the box and are tested in one pass. To 1/4 create constant conditions despite reflections, a closed test box with customised lighting is employed. Four individually controllable RGBW bars allow for different colours and lighting angles to make various defect patterns visible. The coordinated interplay of lighting, image quality, and AI evaluation was crucial. AI-based Inspection System: Arranged components in the Eurobox during optical inspection. The image capture is performed by a monochrome industrial camera of the type IDS uEye U3-36P0XCP-M GL Rev. 1.2. It is based on the 19.80 MP sensor AR2020 from onsemi, delivers 5K UHD resolution with 5136 × 3856 pixels, and is suitable for inspecting the finest surface details. High-contrast representation The 1/1.8-inch rolling shutter sensor in a 4:3 aspect ratio supports detailed imaging of even the smallest defects. The system is complemented by an IDS lens with a focal length of 8.5 mm (Type 20M11-C08528). “For us, it was crucial that we could capture many arranged components on a large testing area in one step while still reliably detecting the smallest surface defects. Only the interplay of lighting, high-resolution image capture, and AI evaluation makes this quality control robustly manageable,” underlines Edwin Schweiger, Co-Founder and COO at Danube Dymamics. The camera captures the entire Eurobox in high resolution. The image data obtained in this manner enables the detection of the smallest defects in each individual component using AI subsequently. What is crucial is not only the pixel count but also the repeat accuracy under defined lighting conditions. The monochrome version additionally supports a high-contrast representation of relevant surface features. AI detected deviations “Especially with highly reflective surfaces, it is essential to depict fine differences stably and in detail,” emphasises Jürgen Hejna, Product Owner 2D Cameras at IDS. “The camera's high sensor resolution and easy integration provide a solid foundation for industrial applications.” Ease of integration was also a decisive factor for Danube Dynamics. The camera can be integrated into the overall system via a standard interface. This reduces the development effort and ensures stable testing results during ongoing operations. Measurable benefit - The potential of the solution became evident during the first live deployment: The AI detected deviations that even experienced professionals hardly noticed. Above all, the significantly reduced testing time made the benefit immediately measurable. The previously manual visual inspection of more than 30 seconds per Eurobox has been reduced to under five seconds. The basis for this consists of four defined lighting scenarios, from which four images per component are generated. Subsequent AI inference The subsequent AI inference occurs with a runtime of approximately 10 milliseconds per cylinder. At the same time, the testing process has been fully digitised. Testing results are now systematically documented and statistically evaluated. Scrap and deviations that were previously not recorded are now transparently traceable. Manual quality control is therefore not replaced but specifically supported. Employees are relieved, testing processes are reproducible, and quality is measurably integrated into the production process. Another milestone is the ability to retrain the AI independently. EVVA can integrate new product variants and error patterns into the system by itself. This enhances the future viability of the solution and allows for adjustments to growing requirements without altering the fundamental system structure. AI-based evaluation The demands for automated quality control are increasing. At the same time, awareness is growing regarding what is possible with coordinated image capture and AI-based evaluation. While standard applications are relatively simple to implement today, this project demonstrates the potential in the inspection of demanding surfaces. It illustrates how even optically challenging, safety-relevant components can be reliably inspected using lighting, high-resolution camera technology, and AI. Customer - Danube Dynamics Embedded Solutions GmbH is a technology company based in Linz, Austria, which has specialised in intelligent embedded system solutions for industry since 2020. The company develops tailor made solutions at the interface of software, AI and electronics with the aim of driving automation and digitalisation forward in an efficient, secure and future-oriented manner through "AI at the Edge". Mechatronic access solutions Today, Danube Dynamics has over 30 customers across Europe and employs a team of more than 15 highly qualified developers and engineers. For over 100 years, EVVA has been synonymous with mechanical and electronic access systems at the highest technical level. What began in 1919 with the founding of the ‘Invention-Testing-Utilisation-Institution’ (EVVA) is now a central part of the company philosophy: EVVA conducts its own research, develops and produces independently, and realises innovative mechatronic access solutions. As a family-owned business, EVVA is among the most successful companies in the industry internationally: Over 300 patents have been registered; subsidiaries in ten European markets and worldwide distributors ensure international presence.