Smart Vision System for Continuous Material Defect Detection

Scalable Inspection Solution for Fishing Nets, Textiles, and More

---

Introduction

Continuous materials such as fishing nets, textiles, conveyor belt products, and industrial fabrics require precise, real-time defect detection to ensure quality and reduce waste.
Our Smart Vision System combines industrial cameras, advanced optics, and AI-powered analysis to detect defects in real time — even at production speed.

This solution is scalable, meaning a single network and workstation can support up to 10 inspection stations, lowering costs as you expand.

---

Key Features

• Two Camera Options:
  • Line Scan Camera – ultra-high resolution for high-speed, continuous inspection
  • Area Scan Camera – cost-effective for moderate-speed applications
• AI Machine Learning – detects holes, tears, and pattern irregularities
• Industrial-Grade Components – built for 24/7 operation in harsh environments
• Scalable Architecture – shared network, workstation, and software for multiple stations
• Web-Based Interface – operators can monitor defects and generate reports from any browser

---

System Diagram

flowchart TB
    A["Material on Conveyor"] --> B["Camera (Line Scan or Area Scan) + Computar V2518FIC-MPYIR Lens"]
    B --> C["Workstation (Shared)"]
    C --> D["GigE Switch (Shared)"]
    D --> E["Database & AI Server"]
    C --> F["Operator Dashboard"]
    C --> G["Reports & Alerts"]

---

Technology Comparison

Feature	Line Scan Camera	Area Scan Camera	Laser Profiling / 3D Sensor
Best For	Continuous, high-speed materials (fishing nets, textiles, films)	Medium-speed inspection, general defect detection	Surface topology inspection, 3D defect analysis
Resolution	Extremely high (1 pixel per line × object length)	Limited by sensor megapixels	Depth + 2D resolution
Speed	Very fast, ideal for moving objects	Slower, depends on exposure time	Moderate, limited by scanning rate
Lighting Requirements	Needs stable, uniform illumination	Needs good lighting but more flexible	Often uses built-in laser light
Cost	Higher camera cost, encoder required	Lower camera cost, no encoder needed	Higher sensor cost than area scan
Software Complexity	Moderate (line-by-line image assembly)	Lower	Higher (3D point cloud processing)
Scalability	Excellent for multiple stations	Excellent	Good but higher per-unit cost
Example Use Cases	Fishing nets, plastic film, paper rolls	Textile QC, sheet metal inspection	Crack depth measurement, roughness inspection

---

Hardware Components

Per-Station Hardware (Camera + Lens + Mounting)

Line Scan Version

• Basler R2L4096-84G5M
• Computar V2518FIC-MPYIR Lens
• Rotary Encoder for precise trigger timing
• Mounting brackets & cabling

Area Scan Version

• Basler a2A4504-5gcIP67
• Computar V2518FIC-MPYIR Lens
• LED Lighting for uniform illumination
• Mounting brackets & cabling

---

Shared Network Equipment (One-time, supports up to 10 stations)

• Cisco CBS350-24P-4X GigE Switch
• Intel X550-T2 Dual-Port 10GbE NIC
• Industrial-grade Cat6a cabling

---

Shared Workstation (One-time, supports up to 10 stations)

• Lenovo ThinkStation (i5-14400, 32GB DDR5, RTX 4000 Ada, 1TB SSD, RAID HDD)
• High-performance GPU for real-time AI processing

---

Software

Our software is built with Django + DRF for robust backend processing and a responsive web dashboard for operators.
Core Features:

• Real-time defect detection with AI models
• Historical data storage and trend analysis
• Multi-station monitoring from one interface
• Automated alerts and defect reports
• Role-based access control for operators, managers, and engineers

---

Scalability Advantage

Unlike single-purpose vision systems, this design allows adding more inspection stations without major additional costs.
Shared infrastructure (network, workstation, and software) means the cost per station drops significantly as you scale.

---

Example Costs (THB)

1 Station – Line Scan: 1,003,062 THB
5 Stations – Line Scan: 1,325,914 THB (265,183 THB per station)

1 Station – Area Scan: 992,062 THB
5 Stations – Area Scan: 1,275,914 THB (255,183 THB per station)

---

Conclusion

Whether you’re inspecting fishing nets, textiles, or any continuous product, our Smart Vision System delivers accuracy, speed, and scalability.
By combining industrial cameras, advanced optics, and AI defect detection, manufacturers can reduce waste, improve quality, and scale cost-effectively.

📩 Contact us today to schedule a demo or discuss your specific inspection needs.