Automated weld seam inspection with AI
Fully automatic visual inspection of weld seams
Ensure the highest weld quality – based on international standards
Our system enables the visual inspection of weld seams in accordance with globally recognized welding standards:
- ISO 5817: Defines quality levels and acceptance criteria for weld imperfections in steel, stainless steel, titanium, and nickel.
- ISO 10042: Applies specifically to aluminum welds and sets limits for acceptable deviations in aluminum arc welding.
- ISO 6520-1: Serves as the classification basis for all welding imperfections and defines the types and categories of weld seam irregularities.
These standards ensure an objective, repeatable, and traceable assessment of weld quality across all production batches.
Weld Testing
With the IUNA AI Weld Inspector you can automate various testing and inspection steps:
- Is the weld seam there?
- Is the weld seam within the predefined tolerance range?
- Automatic detection of irregularities in the weld seam
- Automatic detection of cracks, pores, open end crater blowholes, burn-through, spatter, excessive asymmetry in the fillet and other defects that can be expected in normal production
Precise AI Analysis
Our AI-powered system precisely analyzes each weld seam, identifying the tolerance range and performing detailed segmentation. The IUNA AI Weld Inspector can detect even the smallest defects that might be invisible to the human eye.
The system automatically determines whether a weld seam is within the acceptable tolerance range and highlights any areas that require attention. This ensures consistent quality control and reduces the risk of defective parts reaching the next production stage.
- Precise tolerance measurement
- Advanced segmentation algorithms
- Real-time defect detection
Modular design for maximum flexibility
Our complete turnkey system includes all hardware and software components for reliable weld seam inspection
Intuitive User Interface with 3D Visualization
The user interface is hosted directly on the IUNA AI Server and can be accessed via any web browser from any PC with network connection to the server. No additional software installation required.
Interactive 3D Viewer
Rework operators can see at a glance which weld seam on the product requires rework - highlighted in red for NG (not good) and green for OK.
Real-time Results
Instant visualization of inspection results with detailed defect information and classification.
Browser-Based Access
Access from any networked device - no client software installation needed.
Industrial Camera
- High-resolution industrial cameras
- Including lenses and mounting
IUNA AI Server
- AI inference for image processing
- Available in 19″ rack housing
PLC
- PROFINET Simatic or EtherNet/IP
- Seamless line integration
Vision Light
- Industrial LED lighting
- Optimal weld seam visibility
Flexible System Integration Options
The IUNA AI Weld Inspector can be easily integrated into your existing production environment via the included PLC. Choose from three flexible camera configuration options to match your specific production requirements.
1. Robot-Mounted Industrial Camera
The industrial camera is mounted on the robot arm, allowing flexible inspection of stationary parts from multiple angles.
PLC Compatibility
The IUNA AI Weld Inspector supports industry-standard communication protocols:
- PROFINET Simatic PLCs
- EtherNet/IP Allen-Bradley PLCs
Robot Compatibility
Full support for all major industrial robot brands:
- KUKA
- FANUC
- ABB
- Yaskawa
Complete Turnkey Solution
We deliver the complete hardware package including industrial camera technology and accessories such as lenses and tripods, light sources, PLC, and if required, the enclosure (inspection cell). We also handle on-site commissioning, so you can integrate the complete ready-to-use system into your production without any prior knowledge.
Advantages of Automated Visual Weld Seam Inspection
See why leading manufacturers choose the IUNA AI Weld Inspector over laser-based and ultrasound systems
Image Capture in Less Than 0.5 Seconds
The AI Weld Inspector flies over the seam (or the part moves past the camera), and the result is available immediately. We don't slow down your production line - we keep pace with it.
vs. Laser-Based Systems
Significantly More Cost-Effective
No expensive 3D laser profile sensors required - just high-resolution industrial cameras
Much Faster Inspection
Extremely fast cycle times that don't slow down your production
Superior Detection for Low-Height Welds
Detects fine details where laser systems reach their limits
vs. Ultrasound Testing
100% Inline Inspection
We inspect every single part in cycle time - no offline sampling required
No Part Contamination
Non-contact inspection keeps your parts clean and ready for the next process
Low Maintenance
No coupling agents, no wear parts - reliable operation with minimal upkeep
One-Click Complete Reports
Our customers love the ability to generate complete inspection reports with a single click. See exactly which weld seams are causing problems, how many welds across how many products are defective on average, and track quality trends over time.
- Identify problematic welds instantly
- Average defect rates across products
- Historical trend analysis
- Export to PDF, CSV, or integrate via API
Drop-in Solution
Ready to integrate into any robot cell without extensive modifications
Real-Time Results
Operates in production cycle time with instant pass/fail decisions
Consistent Quality
Eliminates human error with objective, repeatable inspections
Our proven implementation process ensures a smooth integration
Our proven implementation process ensures a smooth integration of the IUNA AI Weld Inspector into your production environment:
Evaluation of Use Case
Contact us. Together, we will check your use case and the implementation options. After that we will select the required hardware components.
System Installation
We integrate all required hardware into your production process: industrial camera, IUNA AI Server, PLC, lighting system, and if necessary an inspection cell. We also install and configure our AI vision software.
AI Model Teaching & Configuration
The first image data is used to teach the AI inspection software. Even a small amount of images is sufficient for this.
Autonomous Inspection
From now on, the IUNA AI Weld Inspector takes over your inspection fully automatically. With the help of advanced AI vision models, you achieve consistent, objective quality control that is far superior to manual inspection.
Ready to automate your weld seam inspection?
Contact our team to schedule a personalized demonstration of the IUNA AI Weld Inspector.