Capabilities

• Automatic workpiece alignment — cameras determine position and orientation, transmitting coordinates to CNC in seconds, eliminating manual measurements and setup errors;

• Tool wear monitoring — optical inspection detects cracks, chipping, and excessive wear; the system notifies the operator or stops the machine if critical;

• Integrated quality control — in-line inspection of dimensions, geometry, and surface condition without additional manual steps;

• Positioning and loading — guiding robotic arms for precise workpiece placement in chucks and fixtures.

Implementation Example

Synetra Iris for CNC turning machines.

What the system does

• Verifies dimensions: length, diameter, chamfers, grooves;

• Detects surface defects: scratches, chips, scoring;

• Confirms correct machining operations (threads, grooves, etc.);

• Commands the robot to sort parts (pass, recheck, scrap);

• Saves photos and measurement logs to MES.

Result

• 100% elimination of manual control;

• No missed machining operations;

• Geometry stability improved by 35%;

• Labor savings — minus 3 operators per shift;

• Complaints on geometry reduced to <0.6%.

Capabilities

• Defectoscopy of castings and forgings — AI-driven detection of cracks, pores, cavities, and surface defects invisible to the human eye;

• Weld seam inspection — checking geometry, continuity, and length; detecting undercuts, porosity, cracks, and missing welds;

• Real-time weld monitoring — laser and video sensors track seam position, automatically correcting robot trajectory;

• Thermal process monitoring — IR cameras track heating/cooling during forging, welding, and heat treatment for consistency.

Implementation Example

Synetra Iris for casting and welding quality inspection.

What the system does

• Inspects castings or welded joints from multiple sides;

• Detects cavities, cracks, undercuts, porosity, slag;

• Compares shape and size to CAD/3D models;

• Verifies weld seam quality and continuity;

• Classifies defects and sends data to MES/QC.

Result

• Up to 97% defect detection without human operators;

• Hidden defect rate reduced by 60%;

• 100% elimination of human error during inspection;

• Stable heat treatment control;

• Internal rework after welding reduced to <0.8%.

Capabilities

• Dimensional inspection — measurement of diameters, radii, angles, distances with micron-level accuracy;

• Form and tolerance control — comparison against CAD models or references, detecting warping, bending, ovality;

• Surface quality and roughness — non-contact inspection for scratches, dents, grooves, and micro-defects;

• Assembly verification — ensuring all components are present and correctly positioned, preventing mix-ups and incomplete assemblies.

Implementation Example

Synetra Iris at an automated assembly line.

What the system does

• Measures holes, chamfers, protrusions, and critical distances;

• Checks form: straightness, parallelism, perpendicularity;

• Detects missing or misaligned parts;

• Performs optical roughness inspection.

Result

• Dimensional accuracy up to ±0.01 mm;

• Assembly defects reduced by 85%;

• 100% detection of missing elements;

• Inspection time per unit reduced 4x;

• Repeatability of quality increased by 40%.

Capabilities

• Optical Character Recognition (OCR) — recognition of alphanumeric codes and serial numbers, even with low contrast or contamination;

• Barcode and DataMatrix scanning — high-speed reading of 1D/2D codes, even multiple items in motion;

• Movement and history tracking — digital passport for each part through all production stages;

• Verification and aggregation — compliance check between item and packaging codes, preventing shipment errors;

• Automated reporting and statistics — seamless integration with MES/ERP for production analytics.

Implementation Example

Synetra Iris at a packaging and logistics area.

What the system does

• Reads laser engravings, DataMatrix, QR, and serial numbers;

• Validates readability and correctness;

• Matches marking with part specifications;

• Scans packages automatically without manual effort.

Result

• 100% elimination of marking errors;

• Inventory registration speed increased 6x;

• Full real-time product traceability;

• Sorting and duplication errors reduced by 80%.

Capabilities

• PPE detection — verifying helmets, goggles, gloves, and uniforms;

• Restricted zone monitoring — preventing entry into hazardous areas, automatically shutting down equipment if breached;

• People counting and presence control — monitoring occupancy in restricted zones, signaling on violations;

• Behavioral analysis — recognizing unsafe actions, detecting smoke, fire, or sparks.

Implementation Example

Synetra Iris at a machine-building plant.

What the system does

• Detects presence and compliance with PPE;

• Identifies people entering danger zones;

• Recognizes accidents (falling, fire, smoke, sparks);

• Reports incidents in real time.

Result

• Workplace safety violations reduced by 90%;

• Response time to incidents — under 1 second;

• 100% elimination of human factor in safety monitoring;

• Downtime from accidents reduced by 35%.

Advantages of Implementing Machine Vision in Metalworking

• Enhanced quality and reduced scrap with 100% inspection;

• Early defect detection for process optimization;

• Increased productivity without line stoppages;

• Full traceability of parts and assemblies;

• Consistent and objective quality control.

Why Choose Us

• Proprietary algorithms optimized for metal industry conditions;

• AI-powered defect classification for high precision;

• Integration with CNC, robots, MES/ERP — unified production ecosystem;

• Full technical support — from design to 24/7 maintenance.