VISION · INDUSTRIAL INTELLIGENCE
AIOR Vision ties what the cameras see to named points on the part's digital twin: every part is recorded automatically, and deviations from the plan are flagged.
Capabilities
Camera images, read-only line signals and the part's digital twin are evaluated together, and every capability rests on the same part record.
Thermal and visible-light cameras are integrated into the cell, and their images can be watched live on the station screens. Camera positions are chosen to suit the cell and the part.
The cameras are calibrated to the part's digital twin; the events they see are matched to named points on the 3D model and tracked under the same name on every part.
Each part's record is compared with the plan. Missing, unexpected or repeated operations and unexplained events (for example, heat that falls on no planned point) are flagged as deviations from the plan.
Every part is recorded under the ID the line sends, such as its barcode, and its history is found by that ID.
Heat maps, point rankings, production history, OEE charts and the Capability Study are on the station screens; a copy of the same records is available to authorised users in the customer portal.
Recording starts and stops on the line's own cycle signals, with no extra step for the operator.
How it works
The steps run on the station by themselves in every cycle.
The cameras watch the cell from different sides. The software looks for the moment a monitored event begins (for example, new heat in the thermal image) and evaluates together the images from every camera that saw it.
The line's PLC reports when a cycle starts and ends. An ID such as a barcode identifies the part, and the machine provides the part's current position.
The event is projected onto the 3D model with the part in its current position and matched to a named point. Cases that cannot be told apart are not forced onto a point; they are marked as uncertain.
The operation is recorded with the part ID, the time and its named point, and compared with the part's plan. Deviations are flagged, and the results appear on the station screens and in the customer portal.
Part record
The record brings together what the cameras saw and what the line reported.
A barcode or other part ID read from the line. Cycles that arrive without an ID are shown separately.
Cycle start and end times, cycle duration and, if the line sends it, the part type.
Each operation's named point, start time, moment within the cycle, duration and status.
The cameras that saw the operation and the part's position at that moment; every decision rests on this evidence.
These statuses state whether operations were seen and which points they were written to; they are not a verdict on the operations' physical quality (for example, weld quality).
Application areas
AIOR Vision is set up for each cell's parts, operations and line signals, and the result is measured in your cell with a planned trial.
In AIOR Vision's first application, thermal cameras in welding cells watch the welding arcs. Each detected weld is written to its named point on the 3D model and, through the barcode, to the part's record; welds that do not match the plan are flagged.
In process steps where heat is decisive, thermal cameras track where on the part heat begins, when it begins and how long it lasts; unexpected heat is flagged.
Where no single camera sees the whole part, the cameras are calibrated to one shared digital twin; an event is written to the part's record once, however many cameras see it.
The plan defines which operation belongs at which point for each part type; each part's record shows, under the part's ID, whether the plan was followed on that part.
Parts produced, cycle times and OEE factors are calculated from the line's cycle signals and tracked by shift, day and period.
Welding traceability application
Below are the screens of the welding traceability application, under the names the station uses. All of them are on the station; those tagged Portal are also in the customer portal.
The 3D model of the part in progress: points with a record in red, the others in blue, with the order of the operations beside it.
How often each point was recorded per part in the chosen period, shown on the model with a colour scale.
Points ranked by their average observations per part.
The list of parts; for a selected part, its 3D model, recorded operations and operation times.
Barcode lookup: the part's own 3D model and its recorded operations.
Parts produced, median cycle, OEE factors and operation records per part, by shift, day, 7 and 30 days.
The station's production summary and median PLC cycle.
A planned verification trial: capture and correct-recognition rates, 95% confidence intervals and a PDF report.
Security
AIOR Vision sends no commands to the production cell or line: it observes, records and reports.
How the system is built
The PLC connection only listens: no data, acknowledgements, tag writes or program changes are sent, and no motion is ever commanded.
Detection and recording run on the station PC; recording needs no internet connection. The server pulls from the station only the records the portal needs.
Backups of the database are made regularly and kept on the station.
AIOR issues portal accounts to the people a contracted customer authorises. Each account is personal and sees only its own organisation's data.
Tell us about your cell, your parts and the operations you want to monitor, and we will plan together how to set up AIOR Vision on your line.
