Weld Contrast Opto solino RTI sensor
Detecting micro defects using BRDF computational imaging
Customer Task:
Welded metal assemblies are widely used in precision mechanical structures, automotive components, industrial housings and welded frames. In many applications, 90° or other angled weld joints must meet strict quality and safety requirements because weld defects can affect structural integrity, durability and long-term reliability. Manufacturers require reliable inspection methods for:
- corner weld seams and fillet welds in 90° joints
- welded brackets and frames
- welded sheet metal assemblies
- structural and functional weld connections
The goal is to detect weld defects early in the production process and ensure consistent quality across all welded components.
Inspection Challenges:
Inspecting 90° weld seams is particularly challenging for traditional machine vision systems.
Typical challenges include:
- complex 3D geometry of corner joints
- changing reflectance of metal surfaces
- strong shadows caused by steep angles
- weld beads with irregular surface structures
- small defects hidden in weld transitions
Standard camera systems rely on fixed illumination and often fail to reveal subtle weld defects. Surface irregularities may only become visible when the weld seam is illuminated from very specific angles.
As a result, many weld inspections still rely on manual visual inspection, which can be subjective and inconsistent.
Technology Principle
The solino RTI sensor uses BRDF-based computational imaging to reveal weld surface structures that conventional imaging cannot reliably detect.
Within milliseconds the system captures a series of 64 images under multiple illumination directions and reconstructs the surface reflectance information computationally. Key elements include:
- 64 multi-directional LED illumination
- photometric stereo image capture
- reflectance-based surface reconstruction
- computational defect enhancement
This approach creates a stable and repeatable inspection environment independent of external lighting conditions.
.
Application
The solino 10×10 RTI sensor can be used to inspect welded assemblies directly after the welding process or during final quality inspection. Because the system captures the surface under 64 illumination directions, weld defects become visible with enhanced contrast. Typical inspection targets include.
- corner weld seams in sheet metal parts
- welded brackets and housings
- structural 90° joints
- weld bead transitions between surfaces
- surface finish of welded components
Original RGB image vs. solino Structural CPI Image
Original RGB image vs. solino reflectance CPI Image
Technology Benefits
Using controlled multi-directional illumination, solino enhances the visibility of surface anomalies on metallic weld seams such as:
- Cracks, Pores and Inclusions
- Undercut and Incomplete Fusion
- Spatter, Burrs as well as surface Roughness variations
- Geometry deviations in the weld bead
The technology works particularly well on metallic weld surfaces where traditional machine vision often struggles due to reflections and complex geometry.
Original RGB image vs. solino Surface Anomaly CPI Image
Solution Architecture:
Item nummer: 100-SO-10-MAN-001 solino 10x10 - Viewer - Stand man
The inspection system consists of:
- solino RTI sensor
- integrated dome illumination with 64 LEDs
- high-resolution 20MP industrial camera
- solinoStudio inspection software and batch acquisition and processing
- The compact sensor design allows easy integration into production machines.
Inspection workflow:
- Component is positioned under the solino sensor
- The system captures a series of images
- Computational algorithms reconstruct the surface reflectance information
- solino studio allows image capturing and processing
Conclusion
The solino RTI sensor combines controlled illumination and computational imaging to reveal surface structures that are difficult to detect using traditional camera systems.
This enables reliable automated inspection of 90° weld seams, supporting manufacturers in improving weld quality, reducing inspection variability and ensuring consistent product reliability.
Additional Image processing and AI available on request
Want to see solino® in action or discuss your specific application?
See solino® in action — book a live demo.
Let’s discuss your application — book a call with our expert.