With camera-based 100% sorting, every cold-formed component is inspected fully automatically using high-precision optoelectronic measurement technology.
State-of-the-art image processing systems analyse critical features in real time and ensure that only components meeting the defined specifications proceed to the next production step.

This seamless inspection process reliably detects even minimal deviations and ensures stable, repeatable production processes — enabling error-free downstream processing.

State-of-the-art sorting systems equipped with up to six cameras are used for camera-based 100% sorting.
Depending on the application requirements, glass disc and slotted disc systems are employed, enabling precise, fully automated inspection of all relevant component features.

Different camera technologies ensure reliable defect detection.
Line-scan cameras provide high-resolution images even for rotating or moving components and are particularly suitable for cylindrical or elongated geometries.
Telecentric optics deliver distortion-free images with maximum dimensional accuracy, making them ideal for precise measurement of contours and diameters.

Additional sensors can be integrated depending on inspection requirements, including surface analysis sensors and eddy current systems for crack detection and hardness testing.

This combination of industrial image processing, specialised camera technologies and sensor systems enables reliable defect detection and consistent component quality.

1. Glass Disc System

Operating Principle

The glass disc system uses a rotating glass plate that feeds the components individually via a vibration feeder or supply unit.
The parts lie flat on the glass surface and are inspected through the glass by one or more cameras.
Illumination units positioned beneath the plate provide high-contrast visualisation of the components.

Advantages

• Ideal for flat or rotationally symmetrical components (e.g. sleeves, bushings, nuts, flat cold-formed parts)
• Very precise inspection of contours and edges, as the glass disc ensures stable component positioning

Limitations

• Less suitable for upright or complex geometries
• Components with small contact areas may shift or tilt during rotation
• Certain features, such as cross holes or internal geometries, are difficult to inspect

2. Slotted Disc System

Operating Principle

The slotted disc system uses a rotating disc with precisely machined slots matched to the geometry of the components.
The parts are positioned and fixed in the slots either vertically or horizontally.

This enables almost complete 360° inspection of the component circumference using lateral cameras.

Advantages

• Particularly suitable for cylindrical, rotationally symmetrical and complex components (e.g. bolts, rivets, sleeves)
• Precise inspection of cylindrical geometry and length dimensions
• Lateral cameras detect surface defects that may not be visible with glass disc systems
• Improved inspection of cross holes, grooves and similar geometrical features

Limitations

• Only suitable for components that can be securely positioned in the slots
• Slot geometry must be adapted to each component type, resulting in lower flexibility than glass disc systems
• The slot geometry can create camera shadow areas, depending on component size and slot depth

Optoelectronic sorting is highly efficient, but not completely error-free.
A sorting rate of 99.9% means that out of 1,000,000 inspected components, up to 1,000 defective parts may remain undetected in the inspection process — depending on the defect type, component geometry and inspection conditions.

With camera-based inspection systems, however, residual defect rates of up to 10 ppm per defined sorting feature can be achieved.
This corresponds to a maximum of 10 undetected defects per million inspected components per feature and represents a very high level of quality in automated sorting processes.

For particularly sensitive components, such as silver-coated parts, camera-based inspection systems can reach their physical and process-related limits.
The required separation and positioning of components in the sorting system may involve mechanical contact that can damage delicate surface coatings, especially when soft or sensitive materials are involved.

Highly reflective or shiny surfaces also place high demands on image processing.
Reflections, light refraction and varying contrast conditions can impair measurement accuracy and lead to inaccurate inspection results.

Where the highest requirements are placed on coating integrity, we therefore coordinate closely with our customers.
Together, we determine whether and to what extent optoelectronic inspection is technically appropriate and feasible — or whether alternative inspection strategies should be applied.