Brick Inspection

Around 120,000 concrete blocks run along the Kortmann Beton production line every day. This is a figure at which humans are not able to carry out 100% quality control. With just 1% rejects, automation is the most effective solution for production. Together with ibea, AT Sensors has developed an application that uses a 4090 camera to inspect the surface of the concrete blocks. This system has been firmly established in production since 2014 and sets new standards in terms of speed and reliability.

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AT’s 3D Camera Enables High-Precision Surface Inspection of Concrete Bricks

In order to be able to inspect concrete blocks reliably and in high resolution, ibea has developed an innovative system in collaboration with AT Sensors that can check the quality of around 120,000 blocks a day. The surface inspection is carried out using a 4090 camera from AT. Despite large surfaces, the smallest defects of less than 0.5 mm are reliably detected at high speed and with absolute precision. As a result, quality control no longer leads to delays despite high turnover and production runs extremely efficiently.

Challenge

The biggest challenge in developing the application was the complete customization. In addition, not only the surface size to be scanned, but also the structure of the bricks were a challenge, as they are not smooth but have an irregular structure. Under these circumstances, small defects are difficult to detect and the stones are quickly rejected. A 3D inspection with a large field of view and maximum accuracy at high speed was therefore required.

Solution

We were able to overcome this challenge with the help of specially developed software from ibea and the latest camera version from AT Sensors. Thanks to the 4K 3D camera’s resolution of 4096 pixels per profile and a speed of up to 20 kHz, quality inspection is no longer a bottleneck. The camera’s large field of view makes it possible to inspect 30 bricks at once. Even the smallest defects of less than 0.5 mm are detected reliably and accurately. The system also runs autonomously, which enables continuous production without additional manpower. Efficiency and sustainability are thus raised to a new level.

Your Benefits

High-Speed

The high speed of the sensor enables a fast and efficient inspection of the brick surface.

Field of View

The 3D camera enables a variety of different configurations and fields of view, making it flexible for use in various applications.

Precision

High accuracy thanks to the 4K sensor (4096 pixels) ensures precise detection of surface irregularities and defects.

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