What is surface defect detection and how does it work?

Surface defect detection assesses the surface of each part passing along the line from camera images and flags defects such as scratches, dents, burrs or colour deviations according to defined classes. The result appears in the dashboard and goes to the line controller as a reject signal. Every decision is stored with its own image.

Does surface defect detection need extra hardware?

Partly. The inspection point needs a fixed camera and controlled lighting, because in surface inspection lighting directly determines the result. An existing line camera can be used if its angle and lighting are suitable. Video is processed either on ALGI AI servers or on an Algi Edge device on site, and the system connects to the line controller over dry contact.

Are my existing IP cameras compatible?

Existing IP cameras can be used as long as they provide a stream, but in surface inspection the decisive factors are image detail and lighting. Small defects require the part surface to fill the frame. Share the part type, the smallest defect size and the line speed, and we will assess whether your current camera is adequate before installation.

How long does installation take?

Once the camera and lighting are in place, sample collection begins. Meaningful inspection needs enough images of good and defective parts from your line, so the collection period depends on your production rate. After the model has been adapted, the system first runs in reporting mode and then with the reject connection enabled.

Is surface defect inspection compliant with GDPR and KVKK?

Inspection looks at the product, not at people. The system does not recognize or identify operators and keeps no per-employee records; the stored image is the inspection frame of the part. With an on-site Algi Edge device, video stays on your premises. If operators enter the frame, your existing camera notice obligations still apply.

QUALITY CONTROL

AI Surface Defect Detection

Surface defect detection puts a camera on the production line that flags scratches, dents, burrs or colour deviations on each passing part and sends a reject signal to the line controller. ALGI runs this inspection at line speed on every part, not on a sample. Each decision is stored with its own image, so when a customer complaint comes in, you can look up how that exact part looked as it left the line. Quality stops depending on who was on shift and becomes a record you can query.

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What is surface defect detection?

Surface defect detection is an inspection layer that separates defects on a part's visible surface using camera images. Defects such as scratches, dents, burrs, porosity, weld faults, paint runs and colour deviations are flagged according to the classes you define.

The system does not work from a ready-made rule list; it works from samples collected on your own line. Images of good and defective parts are gathered, defect classes are labelled, and the model is adapted to your line with this data. When a new defect type appears, its samples are added and the class set is extended.

Inspection is performed on every part. Attention that fades towards the end of a shift, or differences in judgement between operators, no longer come into play; the same threshold is applied the same way on every shift, and every decision is logged with its image.

The result is a quality record you can search by line, shift and defect type, which supports both internal quality reviews and the investigation of a customer complaint. When a supplier or customer asks how a batch was inspected, the answer is a set of images and decisions rather than a signature on a checklist.

How does surface defect detection work?

Setup follows three steps.

Set up the inspection point. A camera is positioned at the point on the line to be inspected, together with fixed lighting. For surface defects, lighting angle is often more decisive than the camera itself; reflective surfaces use angled or ring lighting.

Collect samples and define classes. Images of good and defective parts are collected from your line and defect types are labelled. The model is adapted with this data to your part, material and lighting.

Connect the decision to the line. Video is processed either on an Algi Edge device installed on site or on ALGI AI servers. The inspection result appears in the dashboard, and a reject signal goes to the line controller at the same time over dry contact or an industrial protocol. If preferred, decisions are only reported and rejection is left to the operator.

Every decision is stored with the image of the part and a timestamp. This record, reported by shift, line and defect type, is the input for internal quality meetings and for investigating customer complaints. It also shows which defect types are rising, which points the process team to the step upstream that needs attention.

Which industries use it?

Industrial Manufacturing → Automotive → Metals & Steel →

Frequently asked questions

What is surface defect detection and how does it work?: Surface defect detection assesses the surface of each part passing along the line from camera images and flags defects such as scratches, dents, burrs or colour deviations according to defined classes. The result appears in the dashboard and goes to the line controller as a reject signal. Every decision is stored with its own image.
Does surface defect detection need extra hardware?: Partly. The inspection point needs a fixed camera and controlled lighting, because in surface inspection lighting directly determines the result. An existing line camera can be used if its angle and lighting are suitable. Video is processed either on ALGI AI servers or on an Algi Edge device on site, and the system connects to the line controller over dry contact.
Are my existing IP cameras compatible?: Existing IP cameras can be used as long as they provide a stream, but in surface inspection the decisive factors are image detail and lighting. Small defects require the part surface to fill the frame. Share the part type, the smallest defect size and the line speed, and we will assess whether your current camera is adequate before installation.
How long does installation take?: Once the camera and lighting are in place, sample collection begins. Meaningful inspection needs enough images of good and defective parts from your line, so the collection period depends on your production rate. After the model has been adapted, the system first runs in reporting mode and then with the reject connection enabled.
Is surface defect inspection compliant with GDPR and KVKK?: Inspection looks at the product, not at people. The system does not recognize or identify operators and keeps no per-employee records; the stored image is the inspection frame of the part. With an on-site Algi Edge device, video stays on your premises. If operators enter the frame, your existing camera notice obligations still apply.

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