Inspection of Vacuum Interrupters

Surface Inspection

Inspection of Vacuum Interrupters

Maddox AI enables the reliable and automated identification of surface defects such as soiling, metallic abrasion, impact marks, scratches, chipping on ceramics and many other defects.

Product

Vacuum interrupters

Industry

Energy Technology

Total savings / year

60 - 80k €

Customer Request

Our customer produces over 1,000 switch tubes every day, which are inspected 100% manually by at least one specialist per shift. Due to the intricate defects (flaking, scratches, contamination) that have to be found on a complex component geometry with copper and ceramic surfaces, magnifying glasses and special lighting were used in the manual inspection. Despite these tools, the inspection accuracy varied considerably between employees per shift.

With the introduction of Maddox AI, inspection has been fully automated so that defective components are detected accurately and reliably. In particular, components are now inspected consistently across all shifts and according to clearly defined defect criteria.

Before

Previous Inspection System

After

With Maddox AI

Quality control was carried out completely manually, which was very time-consuming and costly.

The quality check is now fully automated, which has significantly reduced the manual effort and considerably increased the efficiency of the checks.

As the test results were not recorded digitally, there was no structured root cause analysis for faulty (NOK) parts.

Thanks to the digitalized inspection process, the reject rate in production has been reduced.

On average, only 20% of the rejected parts were really faulty. 80% of the parts could still be sold without any problems / with minor reworking.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 75%, virtually eliminating re-inspections and avoiding unnecessary costs.

Before

Previous Inspection System

Quality control was carried out completely manually, which was very time-consuming and costly.

As the test results were not recorded digitally, there was no structured root cause analysis for faulty (NOK) parts.

On average, only 20% of the rejected parts were really faulty. 80% of the parts could still be sold without any problems / with minor reworking.

After

With Maddox AI

The quality check is now fully automated, which has significantly reduced the manual effort and considerably increased the efficiency of the checks.

Thanks to the digitalized inspection process, the reject rate in production has been reduced.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 75%, virtually eliminating re-inspections and avoiding unnecessary costs.

100%

Digitized Analyses

75%

Less Pseudo Scrap

15 Month

Investment Payback Period

Would you like to learn more about our solution? – Test for free now!

Inspection of Ball Bearings

Maddox AI successfully automates the inspection of impact points, incorrectly mounted components and scratches on ball bearings.

Inspection of E-Modules

Maddox AI enables the reliable and automated identification of defects such as sheet metal damage, bubbles in the potting, damaged conductor paths and many more.

Inspection Cell for Plastic Seals

By integrating a rotating inspection cell with three cameras in combination with Maddox AI’s software, the plastic seals are reliably inspected 100% of the time.

Fully automated Wire Inspection

Surface Inspection

Fully automated Wire Inspection

Surface defects such as dents, burnt spots, or insulation faults can be reliably and automatically checked using Maddox AI.

Product

Wire

Industry

Energy Technology

Total savings / year

360-650k €

Customer Request

Our customer manufactures transformers where various wire elements are wound at high speeds. The winding systems sometimes operate at over 10 meters per second, making a 100% manual inspection impossible. If a transformer is wound incorrectly, it can lead to complete failure, resulting in significant costs.

Maddox AI has developed a smart camera device that uses mirrors to monitor 100% of the wire’s surface area. This device detects issues such as discoloration, burn marks, and insulation faults.

Before

Previous Inspection System

After

With Maddox AI

It was manually checked in three shifts by an employee on a sample basis. 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.

Since the installation of Maddox AI, no further customer complaints have been received.

Since the inspection results were not digitized, no structured root cause analysis was conducted for the production of non-conforming (NOK) parts.

Thanks to the digitized inspection process, several process optimizations, such as supplier management, have been implemented.

Before

Previous Inspection System

It was manually checked in three shifts by an employee on a sample basis. The detection accuracy varied depending on the inspector.

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

Since the inspection results were not digitized, no structured root cause analysis was conducted for the production of non-conforming (NOK) parts.

After

With Maddox AI

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

Since the installation of Maddox AI, no further customer complaints have been received.

Thanks to the digitized inspection process, several process optimizations, such as supplier management, have been implemented.

100%

Digitized analyses

MES Integration

Enables the use of data for process improvements

180 Images / Second

Inspection speed

Would you like to learn more about our solution? – Test for free now!

Label Recognition on Cardboard Boxes

Thanks to Maddox AI, the codes and labels on different cartons are reliably recognized, read, matched as well as rejected and re-evaluated in case of discrepancy.

Inspection of Medical Syringes

Surface defects such as impurities, burrs and cracks on tips of syringes can now be reliably checked automatically with the help of Maddox AI.

Tractor Inspection

Maddox AI ensures that all relevant parts of a customer-specific order have been correctly mounted on a the customer’s tractor.

Cable Inspection

Surface Inspection

Cable Inspection

Maddox AI enables the efficient and reliable automation of high-voltage cable inspections. It accurately detects and classifies surface defects such as holes, bubbles, weld marks, and other irregularities.

Product

High-Voltage Cables

Industry

Energy Technology

Total savings / year

160 - 180k €

Customer Request

Our customer produces many kilometers of high-voltage cables for power grids every day, where the surfaces have to be checked for defects such as holes, blisters and welds. Previously, the inspection was carried out visually by one employee per shift, which, with three shifts seven days a week, meant a high personnel requirement.

With the use of the fully automated inspection system from Maddox AI, the cables are now inspected efficiently and precisely for all relevant defects using cameras. This has significantly reduced personnel costs and virtually eliminated the need for manual re-sorting.

Before

Previous Inspection System

After

With Maddox AI

Due to the purely manual inspection, the personnel costs were high and time-consuming and cost-intensive re-sorting operations had to be carried out regularly.

Thanks to Maddox AI’s fully automated inspection system, all cable surfaces are now efficiently monitored with cameras, enabling defects to be detected precisely and reliably.

Due to the inaccuracies of manual checks, around two time-consuming re-sorting operations were required each year.

Manual re-sorting has been virtually eliminated, resulting in annual cost savings of over EUR 120,000.

Before

Previous Inspection System

Due to the purely manual inspection, the personnel costs were high and time-consuming and cost-intensive re-sorting operations had to be carried out regularly.

Due to the inaccuracies of manual checks, around two time-consuming re-sorting operations were required each year.

After

With Maddox AI

Thanks to Maddox AI’s fully automated inspection system, all cable surfaces are now efficiently monitored with cameras, enabling defects to be detected precisely and reliably.

Manual re-sorting has been virtually eliminated, resulting in annual cost savings of over EUR 120,000.

100%

End-to-End Solution

0 € Costs

For the expansion to additional defect classes

Up to 5 km / day

Inspection speed

Would you like to learn more about our solution? – Test for free now!

Fully automated Wire Inspection

Surface defects such as dents, burnt spots, or insulation faults can be reliably and automatically checked using Maddox AI.

Inspection of Injection Molded Parts

Surface defects such as improper cutting edges, cracks, scratches, and contamination can be reliably and automatically identified on injection-molded parts with the help of Maddox AI.

Inspection of Ball Bearings

Maddox AI successfully automates the inspection of impact points, incorrectly mounted components and scratches on ball bearings.

Wire Cable Inspection

Surface Inspection

Wire Cable Inspection

Maddox AI’s consistent, fully automated 100% quality inspection reliably detects defects such as wire breaks, knots, corrosion and many other types of defect.

Product

Wire Cable

Industry

Infrastructure

Total savings / year

40 - 50k €

Customer Requirements

Our customer produces many kilometers of wire every day, which are then wound into ropes. The quality control of these safety-critical components is carried out both by installed cameras and by two employees who manually inspect the recorded images again and examine them for defects. The inspectors’ fluctuating inspection accuracy led to both customer complaints and increased scrap costs due to pseudo rejects. The Maddox AI system ensures that no defects are overlooked and that a consistent inspection performance is achieved at all times.

Before

Previous Inspection System

After

With Maddox AI

The quality check is now fully automated, which has significantly reduced the manual effort and considerably increased the efficiency of the checks.

On average, only 50% of the rejected parts were really faulty. 50% of the parts could still be sold without any problems.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 65%, thereby avoiding unnecessary costs.

On average, only 20% of the rejected parts were really faulty. 80% of the parts could still be sold without any problems / with minor reworking.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 75%, virtually eliminating re-inspections and avoiding unnecessary costs.

Before

Previous Inspection System

The quality check is now fully automated, which has significantly reduced the manual effort and considerably increased the efficiency of the checks.

On average, only 50% of the rejected parts were really faulty. 50% of the parts could still be sold without any problems.

On average, only 20% of the rejected parts were really faulty. 80% of the parts could still be sold without any problems / with minor reworking.

After

With Maddox AI

The quality check is now fully automated, which has significantly reduced the manual effort and considerably increased the efficiency of the checks.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 65%, thereby avoiding unnecessary costs.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 75%, virtually eliminating re-inspections and avoiding unnecessary costs.

100%

Digitized Analyses

0 € Costs

for the extension to further error classes

20 Months

Investment Payback Period

Would you like to learn more about our solution? – Test for free now!

Windshield Wiper Inspection

Maddox AI’s fully automated 100% quality inspection reliably detects even the smallest defects on rubber parts with complex geometries.

Inspection of Medical Syringes

Surface defects such as impurities, burrs and cracks on tips of syringes can now be reliably checked automatically with the help of Maddox AI.

Solutions

Use Cases

Offers

Maddox AI Cloud Platform

Surface Inspection

Inspection of Vacuum Interrupters

Customer Request

Before

Previous Inspection System

After

With Maddox AI

Before

Previous Inspection System

After

With Maddox AI

Inspection of Ball Bearings

Inspection of E-Modules

Inspection Cell for Plastic Seals

Surface Inspection

Fully automated Wire Inspection

Customer Request

Before

Previous Inspection System

After

With Maddox AI

Before

Previous Inspection System

After

With Maddox AI

Label Recognition on Cardboard Boxes​

Inspection of Medical Syringes

Tractor Inspection

Surface Inspection

Cable Inspection

Customer Request

Before

Previous Inspection System

After

With Maddox AI

Before

Previous Inspection System

After

With Maddox AI

Fully automated Wire Inspection

Inspection of Injection Molded Parts

Inspection of Ball Bearings

Surface Inspection

Wire Cable Inspection

Customer Requirements

Before

Previous Inspection System

After

With Maddox AI

Before

Previous Inspection System

After

With Maddox AI

Windshield Wiper Inspection

Inspection of Medical Syringes

Cable Inspection

Label Recognition on Cardboard Boxes