Fully Automated Wire Inspection

Surface Inspection

Surface defects such as dents, burnt areas or insulation defects can be reliably checked automatically with the help of Maddox AI.
Energy Technology
total savings year
360-650k €

Customer Request

Our customer manufactures transformers where various wire elements are wound at high speed. The winding systems sometimes run at over 10 meters per second, which makes 100% human inspection impossible. If a transformer is wound incorrectly, this can lead to complete failure, which is associated with considerable costs.

Maddox AI has developed a smart camera device that uses mirrors to monitor 100% of the wire’s entire sheath surface. The device detects discoloration, burning spots and insulation defects, among other things.

Previous Inspection System
With Maddox AI

Random manual checks were carried out in three shifts by one employee. The detection accuracy varied depending on the inspector.

All products are 100% automatically inspected according to a precise defect book definition, resulting in reduced scrap.

The plant received an average of 1-3 customer complaints per year, which had to be manually rechecked.

No further customer complaints have been received since the installation of Maddox AI.

Since the inspection results were not digitized, no structured root cause analysis was performed for NOK parts production.

Thanks to the digitized inspection process, several process optimizations, such as supplier management, could be realized.

100 %
Digitized Analyses
MES Integration
Enables use of data for process improvements
180 Images / Second
Inspection Speed

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