The client company, operating in the industrial automation sector, needed to improve quality control at a critical stage of its production process, characterised by high speed and the need for micrometric precision. The existing system did not provide sufficiently reliable real-time monitoring to detect alignment defects between components during assembly. The client was looking for a solution that could be integrated directly into the automatic machines, capable of providing immediate feedback on the status of the process, reducing the risk of waste and optimising production efficiency. The main challenge was to combine accuracy, detection speed and compatibility with the industrial operating environment.

Romagna Tech developed a tailor-made solution based on a prototype vision system that could be integrated into the production line. The project involved analysing the technical specifications, selecting and integrating hardware components (cameras, optics, lighting, processing units) and developing dedicated software for image processing and real-time control signal generation. The system was designed to detect alignment defects with an accuracy of less than 0.25 mm and a latency of less than 100 milliseconds. Testing was carried out in the laboratory and in a real environment, with support for mechanical and electronic integration into the customer’s machine. The result is a working prototype, validated under operating conditions, which enables automated and reliable quality control.

The solution developed is highly replicable in industrial contexts that require real-time quality control on high-precision, high-speed processes. It can be adapted to sectors such as electronics, biomedicine, advanced packaging and automotive, where continuous and accurate monitoring of components during assembly is crucial to ensure product quality and reduce costs associated with rework or scrap.

• VISION-e S.R.L.