Automated Optical Inspection Systems (AOI systems)

VisionGauge® OnLine Automated Optical Inspection system (AOI systems) are fully-automated 3D inspection and measurement systems capable of delivering high-accuracy results for various applications and industries. Many different configurations are available, depending on the requirements of the application.

High-Accuracy, High-Speed Automated Optical Inspection Systems

VisionGauge® Online High-Speed Automated Optical Inspection systems are the ideal solution for demanding high-throughput, high-resolution applications. These systems are suitable for a wide range of applications requiring automated defect detection and high-accuracy measurements, including  MicroElectroMechanical systems (for MEMS inspection or MEMS measurement), semiconductor and discrete device inspection and measurement, and much  more.

High-accuracy, high-speed AOI systems
VisionGauge® High-Speed, High-Accuracy AOI System inspection area

VisionGauge® Online High-Speed AOI systems are multi-processor based automated inspection systems that support concurrent image analysis and stage motion. It is a complete, fully-contained, self-standing unit in a full gantry configuration (i.e. the camera moves over the parts; the parts themselves do not move).

These systems are available with a resolution as fine as 0.1 micron. Multiple customizations are possible to meet application-specific requirements including modifications to the camera, optics, illumination module, fixtures, and more. An optional LASER module for automated laser profiling can also be integrated. We provide a wide range of travels, short and long, and a high-speed 240 VAC servomotor motion system for rapid, accurate positioning.

VisionGauge® Online High-Speed Automated Optical Inspection systems are powerful, but easy to use and easy to program. Fully-automated inspection and measurement programs (i.e. "recipes") are created and modified using VisionGauge®'s intuitive Graphical User Interface. Programs can be saved to disk and read-in later on, allowing the possibility to manage different inspection routines for different parts.

VisionGauge® OnLine software includes a wide range of inspection and measurement tools, including:

  • Defect detection
  • Color verification
  • Pattern matching
  • High-accuracy measurements
  • Object counting & sizing
  • Assembly verification
  • Image analysis
  • Blob analysis
  • Presence/absence detection
  • Optical character recognition / verification
  • and much more...

Sample videos:

Head-on view

Oblique view

High-Accuracy AOI Systems for 3D Inspection and Measurement

VisionGauge® High-Accuracy AOI Systems are fully-automated, full-color systems capable of high-accuracy measurements, automated defect detection, color verification, optical character recognition, and much more.

Automated Optical Inspection (AOI) system

The systems feature high-precision, crossed-roller movements with 0.1 micron encoder feedback and micro-stepping motor controller capable of ultra-fine movements. All axes can be automated and are controlled using an external multi-axis, 3-speed joystick or on-screen joystick controls.

The built-in "Auto-Focus" provides fast, accurate, and repeatable re-focusing. With VisionGauge® OnLine's intuitive 'teach' mode, it is easy to create part programs, then let the system perform automated measurements. Programs can be automatically loaded, saved, and read-in from disk so they are ready to operate as soon as the part is in place. VisionGauge® OnLine's extensive set of measurement tools and "Auto-Scan" feature is perfect for applications requiring automatic defect detection.

An open-frame stage with a glass insert allows for both transmitted and reflected illumination. Half- and full-bridge configurations are also available - for example, if your application requires heavy loads and long travels. Standard configurations are available 'off the shelf' and non-standard configurations can also be easily accommodated:  We have a great deal of experience with customization and can configure a system to meet your specific requirements.

Small Automated Optical Inspection System (AOI System) for Analog Video

An small model AOI System with an analog camera

Download a pdf with more information about the VisionGauge® High-Accuracy (AOI) Automated Optical Inspection System.

All VisionGauge® Automated Optical Inspection systems are built around the powerful and easy-to-use VisionGauge® OnLine software:

Part Groups Interface in the VisionGauge OnLine software

Using the VisionGauge® OnLine software package, these systems have a simple and intuitive Windows™ interface and include a wide range of fully-integrated tools for imaging, automated optical inspection (AOI) and automated measurements, qualitative Pass/Fail inspection, pattern matching, optical character recognition and optical character verification (OCR & OCV), statistics, databasing, signal processing, reporting and much, much more!

These systems are very easy to program. Everything is done using the mouse & joystick, through VisionGauge's® intuitive graphical user interface making it quick and easy to review results, view images of "pass" or "fail" parts, export data to Excel or any other application, activate built-in SPC (with graphs as well as numerical & pass/fail statistics), etc...

Advanced software tools include:

  • robust and accurate Auto-Focus,
  • wide range of advanced edge-detection based sub-pixel-accurate measurement tools,
  • automatic registration tools,
  • powerful, rotation independent pattern matching tools,
  • color verification tools,
  • "Counting & Sizing" (blob analysis) tools,
  • power zoom,
  • programmable computer-controlled illumination,
  • and more... the software is continuously being updated and improved with new features and inspection tools.

VisionGauge® AOI Systems are widely-applicable and include a vast range of analysis and measurement tools to allow you to successfully solve countless inspection and measurement machine vision applications.

View more information about applications the VisionGauge® Automated Optical Inspection systems have been used to solve in various industries. Also, learn about our powerful and adaptable VisionGauge® Digital Optical Comparators and how they can solve your application.


Machine Vision Products Application Bulletins: