VISIONCHECK-2000-ST series machine vision systems for the inspection of sheet and strip

What is the VISIONCHECK-2000ST vision system?

The VISIONCHECK-2000ST system is a very high performance machine vision infrastructure, designed to display, freeze and store extremely fast production processes directly on the production line.

Through a perfect synergy between precision optical components, engineered lighting and computing power, the system takes photographs at very high speed of products running past at speed. The result is a sharp, crystal-clear image completely free of motion blur, which allows the operator or the analysis algorithm to inspect the material in real time, as if it were completely stationary.

The system was conceived with a specific focus on the world of metalworking. Its main task is to find millimeter-scale anomalies and micro-defects on the surface and on the edges of the material, ensuring that every meter of coil or sheet produced meets the most demanding quality standards imposed by the market.

The architecture of the system: what it consists of

The effectiveness of the VISIONCHECK-2000ST lies in the quality and the perfect integration of its three fundamental components:

1. High-speed, high-resolution camera: the “visual heart” of the system. It uses latest-generation industrial sensors able to acquire tens, if not hundreds, of frames per second at resolutions that allow the image to be enlarged without losing detail. This camera has extremely fast electronic shutter times, essential for “freezing” the movement of the metal strip.
2. Strobe LED lighting system: developed with proprietary Roder technology, this illuminator emits very short flashes of light of very high intensity, perfectly synchronized with the camera acquisition. The use of LED technology guarantees not only uniform lighting free of unwanted shadows, but also a long service life, no thermal maintenance (typical of old xenon lamps) and low energy consumption.
3. Advanced inspection station: an industrial console, fitted with a high-resolution monitor and an industrial PC, which acts as the operating brain for the operator. From here the image can be displayed in real time, slow motion can be activated, the image can be paused (freeze frame), the visual data can be processed or whole sequences can be recorded for archiving and for documenting the process for traceability purposes.

Fields and sectors of application of the VISIONCHECK-2000ST

The VISIONCHECK-2000ST was conceived to withstand and perform in the harsh industrial environments typical of heavy industry.

Steelworks and primary production

In primary steel plants, steel strip comes out at very high temperatures or undergoes extremely rapid cooling and tensioning processes. At these stages the system can be installed for continuous, uninterrupted monitoring of the metal surface, preventing the propagation of defects from the very origin of the material.

Slitter systems (longitudinal cutting lines)

On slitter lines, a master coil is cut into narrower strips by circular blades. If the blades lose their edge or are poorly adjusted, the strip edges will show burrs, irregularities or cracks. The VISIONCHECK-2000ST excels at edge inspection, making it possible to verify the quality of the clean cut in real time. It stands as a technical solution of excellence, highly competitive with international edge inspection systems, offering customized integration and an intuitive interface.

Cross-cutting systems

Even on lines where the coil is leveled and cut into flat sheets, the feed and cutting speed of the guillotine or rotary shear is critical. The system verifies that there are no scratches caused by the leveling rolls and no geometric defects at the cutting point.

Pickling plants

During pickling, the metal is treated with acids to remove oxides and scale. If the chemical or mechanical process is not uniform, stains, streaks or residues remain. The vision system, with its dedicated lighting, is able to enhance the surface contrast so as to highlight immediately the areas that have not been pickled correctly.

Rolling mills (hot and cold)

In rolling mills, the thickness of the metal is reduced by passing it through huge rolls. A defect on the rolling roll (a mark, a dent) will be printed cyclically onto hundreds of meters of sheet. The VISIONCHECK-2000ST instantly identifies these periodic defects, allowing the operator to stop the plant and replace the roll before generating tonnes of scrap material.

Which defects does the VISIONCHECK-2000ST detect?

The purpose of an industrial vision system is to convert the abstract notion of “quality” into objective, measurable visual parameters. Thanks to the high resolution of the camera and to grazing or coaxial lighting designed to measure, the system detects a wide range of anomalies:

• Edge cutting defects: shearing burrs, chipping, stuck-on trim or irregular edges (essential on slitter lines).
• Mechanical marks and scratches: longitudinal or transverse abrasions caused by abnormal friction in the deflector or leveling rolls.
• Streaks and color variations: alterations linked to problems in the chemical baths, defects in the application of the protective oil or traces of rust.
• Scoring and dents: impacts received by the material, inclusions of foreign material pressed into the sheet during rolling (so-called roll “imprints”).
• Local flatness defects: folds, abnormal waviness of the strip and incorrect tensioning.

The big advantage: VISIONCHECK-2000ST vs traditional stroboscopic systems

For years, industry has relied on classic portable or fixed stroboscopes to inspect moving lines. The principle of the stroboscope is based on the “persistence of vision” of the human eye: by emitting a flash of light at the same frequency as the product passes, the eye perceives the image as stationary. But this technology of the past has enormous and dangerous shortcomings, which the VISIONCHECK-2000ST has definitively overcome.

The limit of the human factor

In the traditional stroboscopic system, the whole burden of quality control rests on the shoulders, or rather on the eyes, of the operator. The defect exists only at the exact moment when the operator is looking at the line lit by the stroboscope. What happens if the operator blinks? What happens if they turn away for a moment to adjust a machine parameter? Or if they are on a break? Quite simply: the defect goes unnoticed and ends up straight at the customer. The image is not recorded, it is ephemeral.

The revolution of the digital “freeze frame”

With VISIONCHECK-2000ST, the human eye is taken out of the critical acquisition equation. The digital system takes continuous frames. The image does not vanish into the dark but is transferred to the monitor of the inspection station. The advantages are enormous:

1. Comfortable and safe monitoring: the operator does not have to stare at a dazzling, tiring strip, but watches a comfortable HD monitor from the control cabin.
2. Freeze and slow motion: if the operator notices something suspicious, they can literally “freeze” the image on screen without stopping the physical production line. They can analyze the defect calmly, enlarge it and assess its severity.
3. Independence from human presence: because the images are acquired digitally, the system is “watching” the line 100% of the time, regardless of whether the operator is physically present in that tenth of a second.

The next level: integration of image processing and machine vision software

Acquiring very high quality images is only the first step. The full potential of the VISIONCHECK-2000ST is unleashed when it is combined with advanced image processing software.

Unlike a simple closed-circuit camera system, the Roder system can turn into an automated inspector. Through the installation of dedicated algorithms, the software does not merely show the images on the monitor: it analyzes them pixel by pixel in real time.

Customizable alarm thresholds

The operator or the quality manager can set “tolerance thresholds”. For example, the system can be instructed to ignore scratches smaller than one millimeter, but to generate an alarm (visual, audible, or a signal sent to the line PLC) if it detects an edge cutting defect larger than 3 millimeters or an extended dark dent. This means moving from passive quality control to active, preventive quality control.

Automatic defect recognition

Thanks to modern image processing techniques (and to the provision for artificial intelligence and deep learning modules), the system can classify anomalies automatically. The software can tell an “oil stain” from a “mechanical crack”, allowing maintenance staff to understand immediately which part of the plant is generating the problem (for example lubrication nozzles or worn rolls).

Recording, history and traceability for quality certification

In the Industry 4.0 era, demonstrating the quality of your product is as important as producing it. End customers (for example the automotive, aerospace and appliance sectors) require increasingly documented and certified standards.

The VISIONCHECK-2000ST inspection station is fitted with large storage systems for holding the data. The system makes it possible to:

• Record video sequences: store the critical stages of production for post-mortem analysis or for process optimization.
• Defect database: every time an anomaly is detected, the system saves the image in question with a time stamp (date, time), the position on the coil (footage) and the type of error.
• Automatic reporting: at the end of the coil, the system can generate a PDF report or a log file containing the “defect map” of the coil. This document can be attached to the shipment to demonstrate the integrity of the product supplied, or to downgrade second-choice steel accurately, optimizing sales.

Why VISIONCHECK-2000ST is the definitive investment (and ranks at the top of the market)

If you are considering upgrading your lines with edge or surface inspection technologies, you may have looked at specialized international brands.

Roder enters this segment offering, with VISIONCHECK-2000ST, a technological solution that is not only comparable but in many respects more flexible and customizable. The features that make Roder a winning choice include:

• Italian/European design and support: fast response times for support, spare parts that are easy to obtain and a team of engineers ready to customize the hardware to the specific geometry of your slitter or rolling machine.
• Proprietary lighting: Roder is a long-standing manufacturer of industrial illuminators. Our strobe LED is not a third-party commercial component but is developed in-house to guarantee maximum synergy with the camera shutter times.
• Scalability: the system can start as a simple high-resolution display system and then be upgraded later with complete software modules for image analysis and artificial intelligence, thus spreading the investment (ROI).

Return on investment (ROI)

Implementing the VISIONCHECK-2000ST typically pays for itself in a very short time (often less than 6 months). The saving generated comes from:

1. Drastic scrap reduction: catching a damaged roll or a worn slitter blade after a few meters, rather than at the end of a coil of tens of tonnes, saves an immense amount of material.
2. Zero-defect policy: avoiding the shipment of defective material protects the company from costly penalties, refunds and loss of contracts.
3. Optimization of labor: line operators tire less, do not risk their eyesight on old stroboscopes and can concentrate on higher value-added tasks, leaving the wearing task of constant visual surveillance to the system.

Frequently asked questions (FAQ) about the VISIONCHECK-2000ST system

Contact Roder for a consultation and an on-site trial

Every production line has unique visual challenges. The reflection of stainless steel is different from the absorption of a pickled strip; the cutting burr of an aluminum strip is different from that of copper. For this reason, Roder offers specialized technical consultancy to analyze the feasibility of your quality control.

Do not let defects escape your eyes or those of your operators. Turn speed into an ally, keeping absolute control over every millimeter of material produced.