AI FOR FACTORY AUTOMATION

AI FOR FACTORY AUTOMATION

AI: IT'S EVERYWHERE

From the phones in our pockets to the reality of self-driving cars, the consumer economy has started to tap
into the power of artificial intelligence (AI). AI has emerged as a foundational technology in the speech, text,
and facial recognition that we use in our mobile and wearable devices and is now beginning to be used in
many other applications—from medical diagnostics to Internet security—to predict patterns and make critical
business decisions. This same technology is now migrating into advanced manufacturing practices for quality
inspection and other judgment-based uses.

In essence, AI teaches robots and machines to do what comes naturally to humans: to learn by example.
New, low-cost hardware has made it practical to deploy bio-inspired, multi-layered “deep” neural networks
that mimic neuron networks in the human brain. This gives manufacturing technology amazing new abilities to
recognize images, distinguish trends, and make intelligent predictions and decisions. Starting from a core logic
developed during initial training, AI-enabled neural networks can continuously refine their performance as they
are presented with new images, speech, and text.

AI-based image analysis combines the specificity and flexibility of human visual inspection with the reliability,
consistency, and speed of a computerized system. AI models can precisely and repetitively solve difficult
vision applications that would be tedious to develop and frequently impossible to maintain using traditional
machine vision approaches. These models can distinguish unacceptable defects while tolerating natural
variations in complex patterns. And they can be readily adapted to new examples without re-programming
their core algorithms.

AI-powered software can perform judgment-based part location, inspection, classification, and character
recognition challenges more effectively than humans or traditional machine vision solutions. Increasingly, leading
manufacturers are turning to AI-based solutions to solve their most sophisticated automation challenges.

2 AI for Factory Automation

 MACHINE VISION FOR AI SOLUTIONS CAN BE POWERED BY
ASSEMBLY AUTOMATION DIFFERENT BASE TECHNOLOGIES
Gone are the days when humans directly
managed factory lines. Today, machines automate Edge learning:
manufacturing, assembly, and material handling
tasks. Machine vision systems equipped with Deploy in minutes
precision alignment and identification algorithms Edge learning is a subset of AI in which
and guidance capabilities have made it possible to processing takes place on-device, or “at the
manufacture compact modern components that could edge,” using a pre-trained set of algorithms.
not be built manually. On a production line, machine The technology is simple to setup, requiring
vision systems can inspect hundreds or thousands smaller image sets and shorter training
of parts per minute reliably and repeatedly, far and validation periods than traditional deep
exceeding the inspection capabilities of humans. learning-based solutions.

For decades, machine vision systems have taught

computers to perform inspections that detect defects,
contaminants, functional flaws, and other irregularities
in manufactured products. Machine vision excels at
the quantitative measurement of a structured scene
because of its speed, accuracy, and repeatability. A
machine vision system built around the right camera
resolution and optics can easily inspect object details Missing OK
too small to be seen by the human eye, and inspect
them with greater reliability and less error (Figure 1).

Mismatch Missing

Deep learning:
Human Analyze fine details
Capable of processing large, detailed image
Inspectors
sets, deep learning is designed to automate
complex or highly customized applications. The
technology enables users to analyze vast image
sets quickly and efficiently, while differentiating
between acceptable and unacceptable
anomalies, to deliver accurate results.
Machine Vision
+ Speed
+ Accuracy
+ Repeatability
+ Inspect details too small to be seen by
the human eye

Figure 1. Human inspectors are skilled at learning

by example and appreciating acceptable deviations
from the control. Machine vision, by contrast, offers
the speed and robustness that only a computerized
system can.

3 AI for Factory Automation

 AI Compared to Other Inspection Methods

Compared to Human Visual Compared to Traditional

Inspection, AI is: Machine Vision, AI is:

More consistent Designed for hard-to-solve

applications
Operates 24x7 and maintains the same level of
quality on every line, every shift and every factory. Solves complex inspection, classification and
location applications impossible or difficult with
classic rule-based algorithms.

More reliable Easier to configure

Identifies every defect outside of the set tolerance. Applications can be set up quickly, speeding up
proof of concept and development.

Faster Tolerates variations

Identifies defects in milliseconds, supporting high- Handles defect variations for applications that
speed applications and improving throughput. require an appreciation of acceptable deviations
from the control.

THE CHALLENGE OF VARIABILITY

Traditional machine vision systems perform reliably with consistent, well-manufactured parts. They operate
via step-by-step filtering and rule-based algorithms that are more cost-effective than human inspection. But
algorithms become unwieldy as exceptions and defect libraries grow. Certain traditional machine vision
inspections, such as final assembly verification, are notoriously difficult to program due to multiple variables that
can be hard for a machine to isolate such as lighting, changes in color, curvature, and field of view (Figure 2).

Figure 2. Application developers may

struggle to program complex inspections
involving deviation and unpredictable
defects into a rule-based algorithm.

4 AI for Factory Automation

 Although machine vision systems tolerate some variability in a part’s appearance due to scale, rotation, and
pose distortion, complex surface textures and image quality issues introduce serious inspection challenges.
Machine vision systems struggle to appreciate variability and deviation between very visually similar parts
(Figure 3). Inherent differences or anomalies may or may not be cause for rejection, depending on how
the user understands and classifies them. “Functional” anomalies, which affect a part’s utility, are almost
always cause for rejection, while cosmetic anomalies may not be, depending upon the manufacturer’s needs
and preference. Most problematically, these defects are difficult for a traditional machine vision system to
distinguish between.

Wire present No wire

Figure 3. Confusing and glaring backgrounds can make it difficult for traditional machine vision systems to
appreciate slight differences between images. In this case, an AI-based model sees beyond the metal surface
and specular glare to check for missing wire bands in a car trim assembly.

ADVANTAGES OF HUMAN INSPECTION

Unlike traditional machine vision, humans are adept at distinguishing between
subtle cosmetic and functional flaws, as well appreciating variations in part
appearance that may affect perceived quality. Though limited in the rate at which
we can process information, humans are uniquely able to conceptualize and
generalize. We excel at learning by example and are capable of distinguishing
what really matters when it comes to slight anomalies between parts. This makes
human vision the best choice, in many cases, for the qualitative interpretation
of a complex, unstructured scene—especially those with subtle defects and
unpredictable flaws (Figure 4).

For example, humans are much more accurate when dealing with deformed and
otherwise hard-to-read characters, complex surfaces, and cosmetic defects. For
many of these applications, machines cannot compete with humans for their
appreciation of complexity. Figure 4. Examples of
complex scenes that
human vision excels at
distinguishing.

5 AI for Factory Automation

 AI FOR COMPLEX INSPECTIONS
AI-enabled models can help machines overcome their inherent limitations by marrying the self-learning of a
human inspector with the speed and consistency of a computerized system.

As the examples in Figure 5 show, AI-based image analysis is especially well-suited for cosmetic surface
inspections that are complex in nature: patterns that vary in subtle but tolerable ways, and where position
variants can preclude the use of methods based on spatial frequency. AI excels at addressing complex
surface and cosmetic defects, like scratches and dents on parts that are turned, brushed, or shiny. Whether
used to locate, read, inspect, or classify features of interest, AI-based image analysis differs from traditional
machine vision in its ability to conceptualize and generalize a part's appearance based upon its distinguishing
characteristics—even when those characteristics subtly vary or sometimes deviate.

Figure 5. AI-based image analysis excels at identifying cosmetic and functional anomalies that machine vision
struggles with, and it does so more quickly and reliably than a human inspector.

CHOOSING BETWEEN TRADITIONAL MACHINE VISION AND AI

The choice between traditional machine vision and AI depends upon the type of application being solved, the
amount of data being processed, and processing capabilities. Indeed, for its many benefits, AI is not the right
solution for many applications. Traditional rule-based programming technologies are better at gauging and
measuring, as well as performing precision alignment. In some cases, traditional vision may be the best choice to
fixture a region of interest precisely, and AI to inspect that region. The result of an AI-based inspection may then
be passed back to traditional vision to take accurate measurements of the defect size and shape.

AI complements rule-based approaches, and it reduces the need for AI domain expertise to construct an
effective inspection. Instead, AI has turned applications that previously required vision expertise into engineering
challenges solvable by non-vision experts. AI transfers the logical burden from an application developer, who
develops and scripts a rule-based algorithm, to an engineer training the system. It also opens a new range
of possibilities to solve applications that have never been attempted without a human inspector. In this way,
AI makes machine vision easier to work with, while expanding the limits of what a computer and camera can
accurately inspect. Figure 6 below identifies the most suitable applications for traditional machine vision and for
AI-based approaches, including those well-suited to either.

6 AI for Factory Automation

 When to Deploy Traditional Machine Vision vs. AI-Based Image Analysis

Machine vision AI-based image analysis

Complex cosmetic
Gauging and measurement inspection and segmentation
Inspection and
defect detection

Texture and material classification

Barcode reading and identification OCR

Assembly verification

Part and feature location

Presence/absence

Deformed and variable

feature location
Counting

Robotic guidance
Challenging OCR,
including distorted print

Figure 6. AI-based image analysis and traditional machine vision are complementary technologies,
with overlapping abilities as well as distinct areas where each excels. Some applications may involve
both technologies.

CONCLUSION
Increasingly, industry is turning to AI technology to solve manufacturing inspections too complicated, time-
consuming, and costly to program using traditional rule-based algorithms. This will make it possible to
automate previously unprogrammable applications, reduce error rates, and quicken inspection times. AI offers
manufacturers the possibility to solve problems that challenge traditional machine vision applications, and to do
so with greater robustness and reliability.

7 AI for Factory Automation

BUILD YOUR VISION
2D VISION SYSTEMS
Cognex machine vision systems are unmatched in their ability to inspect,
identify and guide parts. They are easy to deploy and provide reliable,
repeatable performance for common to complex tasks.
www.cognex.com/machine-vision

3D VISION SYSTEMS
Cognex laser profilers and area scan 3D vision systems provide ultimate
ease of use, power and flexibility to achieve reliable and accurate
measurement results for the most challenging 3D applications.
www.cognex.com/3D-vision-systems

VISION SOFTWARE
Cognex vision software provides industry leading vision technologies,
from traditional machine vision to AI-based image analysis, to meet any
development needs.
www.cognex.com/vision-software

BARCODE READERS
Cognex industrial barcode readers with patented algorithms provide the
highest read rates for 1D, 2D and DPM codes regardless of the barcode
symbology, size, quality, printing method or surface.
www.cognex.com/barcodereaders

Companies around the world rely on Cognex vision and barcode reading
solutions to optimize quality, drive down costs and control traceability.

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