Quality Control Challenges in Industrial Laser Marking
In modern manufacturing, laser marking has revolutionized component identification and traceability processes. However, ensuring the accuracy and quality of these markings is a significant challenge, especially in high-volume manufacturing environments. The integration of advanced vision systems with laser markers has overcome these limitations, offering comprehensive solutions for quality control, precise positioning and data validation.
Cameras integrated into laser marking systems are not just an accessory, but a key element that determines the effectiveness of the entire production process, reducing waste and ensuring compliance with quality standards.
Main Applications of Vision Systems in Laser Marking
Vision systems in laser marking applications are mainly divided into four functional macro-areas:
- Auto-centering of marking: Vision systems identify specific reference points on the component and automatically position the marking with millimeter accuracy, even on uneven surfaces or with variations in positioning.
- Code verification and grading: After marking DMC (Data Matrix Code) or QR codes, the cameras immediately verify quality according to international standards such as AIM-DPM, assigning quality grades (A, B, C) and detecting any problems.
- Optical Character Recognition (OCR) reading: Systems can recognize and interpret marked alphanumeric text, confirming the correct legibility of the information.
- Identification of pre-existing codes: Cameras can read markings already on the component, retrieve information from MES/ERP systems, and dynamically determine what to mark next.
Innovative Technologies: Artificial Intelligence in the Service of Marking
The recent evolution of laser marking vision systems has seen the introduction of artificial intelligence and deep learning algorithms that have significantly improved the capabilities of these systems. These technologies enable:
- Faster and more accurate recognition of features in complex industrial environments
- Simplified systems training for new products or variants
- Increased tolerance to variations in lighting, location, and surface conditions
- More reliable quality verification even for markings on difficult surfaces
LASIT has integrated these advanced technologies into its systems, developing proprietary algorithms that optimize reading and verification processes, dramatically reducing false rejects and increasing overall reliability.
LASIT Solutions for Vision Systems in Laser Marking
TTL Vision System (Through The Lens or Coaxial)
The TTL or coaxial system represents one of the most advanced solutions in the field of integrated vision for laser marking. This system uses the same optical path as the laser to view the marking area, ensuring:
- Precise centering: Positioning the marking between the grooves on the face of components with the highest precision
- Immediate DMC validation: Verification of code quality without moving the laser or camera
- Automated decision making: If the marking obtains an A or B grade, the component continues in the production line; if the quality is lower, the operator is alerted by visual and audible alarms.
Customized Side Vision Systems
For applications requiring a wider field of view or greater flexibility, LASIT has developed side-view systems based on high-quality industrial cameras integrated with proprietary software:
- Extended field of view: Up to 90x60mm compared to 20x16mm for TTL systems
- Optimized illumination: Circular outdoor lighting systems that provide a clear view of the entire framed area
- Custom software: Proprietary algorithms for reading, verification and integration with production systems
Case Study: Traceability in the Automotive Sector
A major automotive parts manufacturer needed a system for DataMatrix code marking on die-cast aluminum components, with immediate quality verification and full traceability.
The main challenge was the uneven surface of the castings and the need to integrate the system with the existing production database for dynamic code generation.
LASIT has implemented a system based on:
- 50W fiber laser marker for high-speed marking on aluminum
- Side vision system with industrial camera and dedicated lighting
- Customized software to interface with customer’s MES system
- Deep learning algorithms for optimal marking position recognition
The results included:
- Reduction of rejects due to illegible markings by 98%.
- Cycle time reduced by 30% due to automatic positioning
- Complete traceability of each component through the entire production chain
- ROI (Return on Investment) achieved in less than 8 months
Future Perspectives
The integration of advanced vision systems with laser markers represents the future of industrial traceability. Artificial intelligence technologies will continue to enhance the capabilities of these systems, making increasingly complex applications possible even in harsh manufacturing environments.
LASIT remains at the forefront of this industry, continuously investing in research and development to offer comprehensive solutions that meet the specific needs of each customer.