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Even the smallest series parts are measured accurately thanks to incident-light inspection with high-performance camera systems.

Vision inspection solutions and sorting machines

For 100 percent testing and traceability

Compliance with today's requirements for products and their manufacturing processes calls for continuous improvements to quality and efficiency. Our automated vision inspection solutions and sorting machines feature industrial image processing and help customers to achieve both goals – always with the focus on added value.

Automated optical inspection means efficient 100% testing and sorting of series parts, small parts and bulk goods by automated testing systems – either in the production line, or as standalone solutions, especially for very large quantities. It can guarantee part quality and prevent bad parts – but that's not all. Test results from camera-based industrial image processing also make it possible to identify potential for optimizing production – so users benefit from extra added value.

To investigate the testing tasks you set for us, we carry out a feasibility analysis in our image processing laboratory.

Benefits of vision inspection with automated testing systems from Kistler:

  • In-depth advisory service with feasibility analyses of test assignments in our image processing laboratory
  • 100% testing of series parts, small parts and bulk material
  • Large production quantities and fast cycle times
  • Enhanced process reliability and optimized process efficiency
  • Comprehensive recording and transmission of quality data
  • Reduced quality costs
  • Increased plant efficiency and lower total cost of ownership (TCO)
  • Rapid amortization (RoI)

In addition to its test automation portfolio, we also offer a special laser marking system for continuously produced series parts (marking on the fly). Its purpose: to meet requirements for product traceability. Specialized software, high-performance industrial computers and highly efficient controls allow direct access to the acquired quality data, together with statistical evaluation. Thanks to all these features, our automated test systems play a key part in implementing Industry 4.0.

Test systems for continuous materials in punching processes – KVC 621

The KVC 621 test system for 100 percent inspection of continuous material in punching processes operates autonomously.
The KVC 621 test system for 100 percent inspection of continuous material in punching processes operates autonomously.
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The KVC 621 is a universal, autonomous video measurement system for 100% inspection of continuously produced parts. In this system, the integrated control and image processing components focus on high, individually adjustable processing speeds for complex assignments with transmitted and reflected light.

The KVC 621 test system for continuous material is available in various sizes including an extra-compact version (for confined spaces) and a version with extended installation space (e.g. to accommodate additional cameras or to integrate a marking laser).

Individual testing and sorting functions

  • Conventional dimensional checks
  • Complete contour tracing for errors that occur sporadically
  • Detection of surface defects
  • Individually adjustable error response 

Measurement and sorting machines designed for 100 percent inspection of mass-produced parts

Vision inspection of mass-produced parts with measurement, test and sorting machines of the Kistler KVC 121 series

The automated testing and sorting machines in series KVC 121 ensure high throughput rates during 100-percent inspection of small turned, pressed and punched parts. The inclined-plane principle is applied here, depending on the part geometry and the testing assignment. An integrated, controllable vibratory conveyor feeds the parts for testing, according to their size and weight.

Individual testing and sorting functions during optical control of mass-produced parts:

  • Dimensional accuracy checks
  • Complete contour measurement for errors that occur sporadically
  • Automated surface defect inspection

Equipment features and options

  • Testing rates of up to 250 parts/min
  • Comfortable operator experience thanks to 24" touchscreen
  • Up to four matrix cameras (black-and-white or color) with resolutions of up to 16 million pixels
  • LED flash illumination, transmitted and reflected light (telecentric, coaxial, diffuse)
  • Adjustable vibratory conveyor for the part feed
  • Separating device with swarf separator
  • Triggering by laser light barrier
  • Telescopic tray with keyboard and trackball
  • Control cabinet and 19-inch USP
  • CAQ connection
  • Remote maintenance is possible

Inspection and sorting of bulk material and small parts – with high throughput and accuracy

The sorting machines of the Kistler KVC 821 series are ideal for 360° inspection and 3D measurements of small bulk material.
The sorting machines of the Kistler KVC 821 series are ideal for 360° inspection and 3D measurements of small bulk material.
The KVC 821 automatic rotary plate testing system is designed to optically perform dimensional accuracy and surface checks.

Automated rotary plate testing systems in the Kistler series KVC 821 are the ideal choice to meet the increasing requirements for adaptative surface testing as well as dimensional checking of individual parts Testing is performed on a continuously rotating plate with a glass ring attachment and a regulated servo drive with a friction clutch. Depending on their size and weight, the parts for testing are fed in via an integrated or separate feeder system. The optimum target feed rate can be set with the help of the integrated software.

Individual testing and sorting functions for the inspection of bulk material and small parts:

  • Dimensional accuracy checks on individual parts
  • Adaptive surface inspection thanks to the Trevista reflected light dome illumination unit based on shape-from-shading technology
  • 360°-inspection of inner and outer lateral surfaces
  • Hardness testing
  • Integration of 3D measurement systems

Trevista is a registered trademark of our partner SAC

Rotary indexing testing and sorting machine for complex inspection tasks

Rotary indexing testing and sorting machines of the Kistler KVC 820 series are ideally suited for complex inspection tasks.

Rotary indexing testing and sorting machines are mainly used when the test criteria require parts to be handled in this way. These systems are chosen if the parts for testing have to be presented to one or more cameras in different positions, or if a test object has to be rotated through 360° to scan for outer surface defects.

The central component of the KVC 820 automated testing system is a rotary index plate on which the test objects pass through all the required test stations in sequence. As well as conventional feed components, a SCARA robot can be used to place the test objects on the rotary index plate and remove them from it.

This automated test system can be expanded by adding up to eight digital cameras with different resolutions.

Individual functions of rotary indexing testing and sorting machines:

  • Complex inspection tasks with rotary index plate: geometric, surface, hardness and microstructure tests using various methods and tactile, endoscopic (for internal inspection) and pneumatic testing tools.Complex surface inspections with the Trevista reflected light dome illumination unit which is based on the Shape from Shading technology
  • 360° defect inspection of inner and outer lateral surfaces
  • Optical 3D-measurement and inspection

Complex inspection tasks (various inspections) on sealing and lateral surfaces, e.g. on:

  • Small turned, stamped and pressed parts
  • Highly complex punched and deep-drawn parts for the automotive sector

Equipment features and options

  • Comfortable operator experience thanks to 24" touchscreen
  • Up to eight matrix and line-scan cameras (black-and-white or color) with resolutions of up to 16 million pixels
  • LED flash illumination, transmitted and reflected light (telecentric, coaxial, diffuse)
  • Trevista reflected light dome illumination unit
  • Rotary index plate with workpiece holders
  • Feed via vibratory conveyor, linear conveyor, SCARA robot or handling system
  • Triggering by laser light barrier
  • Telescopic tray with keyboard and trackball
  • Control cabinet and 19-inch USP
  • CAQ connection
  • Remote maintenance is possible

Trevista is a registered trademark of our partner SAC

Optical measurement and sorting machine with feeder robot – manage various tests within one cycle

The Kistler optical measurement and sorting machine with feeder robot KRC 950 manages various inspection tasks in one cycle.

On optical measurement and sorting machines with feeder robot in the ROBOCheck VRC 950 series, all the part handling – feeding, handling, removal – is carried out with a SCARA or six-axis robot which presents the test objects to the various cameras and test stations precisely according to the requirements for the test criteria, positioned as necessary. The benefit: multiple characteristics can be captured in one test cycle.

Individual functions of optical measurement and sorting machines with feeder robot:

  • Complex test assignments and surface inspection
  • Inspection of complex geometries
  • Different combinations of various inspection methods for each test station
  • Complex surface inspections with the trevista reflected light dome illumination unit which is based on the Shape from Shading technology
  • 360° defect inspection of inner and outer lateral surfaces  
  • Hardness testing
  • Optical 3D-measurement and inspection

Complex surface and geometry inspections on the lateral surfaces of turned parts:

E.g. of banjo bolts

Equipment features and options

  • Comfortable operator experience thanks to 24" touchscreen
  • Up to eight matrix and line-scan cameras (black-and-white or color) with resolutions of up to 16 million pixels
  • LED flash illumination, transmitted and reflected light (telecentric, coaxial, diffuse)
  • Trevista reflected light dome illumination unit
  • SCARA or six-axis robots for part handling
  • Triggering by laser light barrier
  • Telescopic tray with keyboard and trackball
  • Control cabinet and 19-inch USP
  • CAQ connection
  • Remote maintenance is possible

Trevista is a registered trademark of our partner SAC

Optical inline inspection systems – compact solutions featuring image processing technology

Optical inline inspection systems as the Kistler KVC 42x und KVVC 350 series are compact retrofittable imaging systems.

Compact systems for general image processing tasks

Automated optical inline inspection systems featuring image processing technology, such as the compact system series KVC 42x from Kistler allow to directly integrate camera stations as modules into existing production lines – i.e. without the complete automated test system. These solutions require an industrial PC for image processing and a control cabinet assembly, which are installed within one common housing.

Advantages of our optical in-line inspection systems:

  • Unrestricted functionality of current image processing software for varied applications in industrial punched and turned part production, and general automation
  • Simple integration into existing production lines thanks to compact dimensions and industry-compliant peripherals
  • Uniform user and menu interfaces
  • No additional external network components are required
  • Image processing components and IPC are interchangeable within the KVC product line

Optical in-line inspection system – 100% control, even when testing is more complex

We offer the KVC 350 automated test system as an additional integration solution for test automation. This system is ideal for testing complex fasteners. It includes multiple test stations (mainly camera-based) that are approached successively with a linear axis. In the basic version, good parts are fed to and removed from the workpiece holder manually, but these operations can be automated at any time with a suitable handling system.

Advanced testing and sorting functions

  • Dimensional accuracy check
  • 360° inspection of lateral surfaces
  • Surface inspections with the Trevista reflected light dome illumination unit
  • Hardness testing
  • Identification of good parts by printer

Optical in-line inspection of complex safety-critical fasteners:

E.g.: Preloading bolts

Trevista is a registered trademark of our partner SAC

Laser marking-on-the-fly (MOF) of continuous materials – high precision combined with high speed

The KLM 621 laser marking-on-the-fly machine from Kistler can be integrated directly into existing punching lines.
The KLM 621 laser marking-on-the-fly machine from Kistler can be integrated directly into existing punching lines.
Laser-marked QR code
A laser-marked continuously punched part
Combination of KLM 621 laser marking-on-the-fly system and KVC 621 testing system for continuously produced punched parts

Our LASERmark KLM 621 laser marking machine comes equipped with all the components needed for strip transportation and labeling of continuously produced punched parts with marking-on-the-fly (MOF). The KLM 621 – it can be used for a variety of materials – is a flexible, high-performance system that operates autonomously and can be integrated directly into punching, injection molding and assembly lines. 

The main purpose of rapid, permanent end-to-end marking and labeling of parts is to ensure traceability – a key factor in quality assurance for every production facility. Parts can also be counted and separated. 

Marking and coding continuous material during the production process is a highly cost-effective method – because there is no need to stop the belt, and setup costs are eliminated. 

Another benefit of laser marking-on-the-fly: the exceptionally high cycle rate of over 2,000 workpieces per minute boosts your manufacturing line's productivity. Our LASERmark KLM 621 is designed for continuous operation. Each workpiece can be individually marked with numbers, characters, codes and safety-relevant features. 

Coupling to the process only requires a release signal and an interface to the master control. 

Production facilities where the KLM 621 MOF laser marking system is used
Punching lines, injection molding lines and assembly lines

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