In the era of smart manufacturing, improving product quality and reducing production costs have become key competitive advantages. As production scales and product complexity grow, manual inspection struggles to meet modern manufacturing demands. Machine vision-powered Automatic Optical Inspection (AOI) technology enhances accuracy and production speed, making it an indispensable tool for quality control in smart manufacturing. AOI is widely applied in inspecting the appearance and dimensions of precision industrial products, such as PCBs, passive components, and metals, helping to improve overall production quality and efficiency.
Limitations and Challenges of Traditional AOI in High-Precision Defect Detection
Traditional AOI systems rely on pre-set parameters for image comparison, limiting their ability to detect defects with subtle shape or color variations or poor angles. This often results in inaccurate defect identification. Operators must have extensive industry knowledge and frequently adjust parameters, which leads to misjudgments when dealing with complex product designs, increasing maintenance challenges and the risk of missed defects. This also adds to the cost of manual re-inspection. As manufacturing shifts toward small-batch, high-variety production, traditional AOI systems struggle to meet the demands. Their inability to process high-resolution images and perform real-time data analysis makes them inadequate for the precise and high-accuracy inspection needs of modern smart manufacturing.
Portwell’s WEBS-45J1, PJAI-100 and PSYS-508 Series: Tailored AOI Performance for Varied AI Computational Needs
WEBS-45J1 System Features:
The WEBS-45J1 series supports Intel® Core™ processors (14th/13th/12th Gen) and expandable memory up to 96GB DDR5, meeting the requirements for efficient image recognition and moderate AI computing. The system offers rich I/O interfaces, including four serial ports and Dual Gigabit Ethernet, along with an M.2 expansion slot compatible with the Hailo-8 AI accelerator, delivering up to 26 TOPS. This enhances inference capabilities and processing power for high-resolution images. Implementing this system significantly improves defect detection and equipment automation on production lines.
PJAI-100 System Features:
The PJAI-100 series features the advanced NVIDIA Jetson Orin SoC module, delivering up to 100 TOPS of AI computing power, making it ideal for handling complex image data. Its high-speed inference capabilities maintain exceptional recognition accuracy even with intricate datasets, significantly reducing false positive rates and enhancing the reliability and efficiency of AOI systems in precision inspection applications. The system is equipped with Dual RJ45 Gigabit Ethernet ports, three USB 3.2 Type-A ports, and supports NVMe SSD, Wi-Fi, and 4G/5G expansion. Its versatile interfaces enable seamless integration with image sensors and other production equipment, meeting the demands for real-time performance and reliability in modern manufacturing environments.
PSYS-508 System Features:
The PSYS-508 4U rackmount industrial series delivers powerful AI processing capabilities, featuring the latest Intel® Core™ processors (14th/13th/12th/10th Gen) and up to 128GB of DDR5/DDR4 memory. It is designed to handle high-resolution images and real-time data, making it ideal for AOI applications in large-scale production environments. Its PCIe and M.2 expansion slots support flexible configurations, including the RTX 4070 GPU or Hailo AI accelerators, providing over 480 TOPS of computational power. This enables efficient processing of complex image and data applications, supporting advanced image processing and deep learning training. It can accurately extract image features and details, such as enhancing contrast and resolution, optimizing image quality, and generating high-quality training datasets. With high-speed inference capabilities, it significantly improves defect detection accuracy. Additionally, the series incorporates an 80 Plus Gold-certified power supply, ensuring energy efficiency and long-term stable operation to meet continuous production demands.
Portwell Edge AOI: Flexible Scalability and Environmental Adaptability, Perfect for Industrial Environments
Portwell’s Edge AOI series offers a complete range of reliable equipment for smart manufacturing, featuring AI computing power levels that cater to various needs, from entry-level to advanced deep learning, meeting the demands of diverse automated inspection scenarios. Systems like the WEBS-45J1, PJAI-100, and PSYS-508 are designed to operate in temperatures ranging from -20°C to 60°C with fanless designs, making them ideal for dust-prone industrial environments. Equipped with rich expansion options and versatile interfaces, these products ensure seamless integration with production equipment, providing stable operation, minimizing failure risks, reducing downtime, and enhancing production continuity.
Portwell’s RPET (Remote Portwell Engineering Toolkits): Simplifying AOI System Configuration and Maintenance
All the above systems are compatible with RPET and feature remote monitoring functionality. They support mainstream operating systems, including Windows and Linux, and come equipped with comprehensive software development tools. From hardware monitoring to system updates, RPET allows real-time tracking of device CPU load, memory usage, disk capacity, and network load. It also enables remote power resetting and shutdown management, simplifying configuration and monitoring while optimizing AOI performance and system maintenance. This tool makes Portwell’s AOI solutions advanced, flexible, and reliable.
WEBS-45J1 | Fanless Box PC | Embedded System
The WEBS-45J1 builds on Intel® desktop Q670E chipset and takes advantages of 14th/13th/12th Generation Intel® Core™ i3/i5/i7/i9 processors technologies that can support dual DDR5 memory and 2x SATA Ports for storage. Support two Gigabit Ethernet ports, One M.2 E Key, One M.2 M Key socket. The WEBS-45J1 is an ideal platform with rich I/O and high resolution for POS, kiosk, digital signage, and factory automation applications.
PJAI-100 Series | Edge AI Computing | Embedded System
Designed with NVIDIA® Jetson Orin™ SOM, Portwell’s rugged and compact PJAI-100 supports a wide industrial temperature range from -20°C to 60°C. Its fan-less design ensures silent operation, reliability, and a low maintenance rate. In addition, it integrates M.2 Type E and M.2 Type B for wireless connectivity, and it supports dual Gigabit Ethernet LAN ports suitable for Edge AI applications and more.
PSYS-508 Series | Rackmount System | Industrial Computer Systems
The PSYS 508 series, designed for factory automation, AOI, and surveillance applications, offers robust performance and flexible configurations. The Q470 model, featuring the Intel® Q470E chipset, supports 10th Gen Intel® Core™ processors with 4 x DDR4 memory and 6 x SATA ports. The Q670 model, built on the Intel® Q670E chipset, supports 12th to 14th Gen Intel® Core™ processors with 4 x DDR5 memory and 7 x SATA ports. Both models include a 600W 80 Plus Gold ATX power supply, delivering reliable and efficient performance for diverse industrial needs.
LEAD-Series | Industrial Display
- Elegant Design: Bezel-free and lightweight, suitable for environments like Automated Sorting Solution.
- Versatile Configurations: Available as PD (monitor only), PND (basic computing), or PPC (Intel Apollo Lake processors).
- Robust Connectivity: PND and PPC models feature Gigabit Ethernet for seamless IoT device integration.
- Durable Construction: The front panel achieves IP65 certification, ensuring resistance to dust and water.
- High-Quality Display: Full HD screens with ten-point multi-touch capability for an excellent user experience.