Complete vision
integration
One engineering path from requirements and feasibility to hardware selection, programming, installation, and commissioning.
Our integration processVISION CONTROLS INC. / MACHINE VISION SPECIALISTS
In operation
since 2002.
Hundreds of successful machine vision projects.
Experience across industries. Engineering for your application. We take manufacturers and machine builders from sample-part testing through installation, commissioning, and support.
Complete integration · Troubleshooting · Upgrades
Specialist vision engineering.
Connected to the whole machine.
Optics & lighting
Vision programming
PLC & controls integration
Hands-on experience.
Application-driven selection.
COGNEXKEYENCE
The right platform
for your requirements.
EXPERIENCE THAT SHAPES THE SOLUTION
The right image.
The right equipment.
A working system.
Our work goes beyond camera programming. We bring machine vision expertise and automation experience to the complete application.
- Prove the approach before the hardware purchase.
- Good and defective samples are tested in our lab with the proposed camera, lens, lighting, and part presentation. Where more evidence is needed, an engineering study can measure performance in greater depth.
- Choose equipment around the application.
- We work across platforms rather than limiting the solution to one camera brand. Use 2D, 3D, line scan, or AI where it makes sense, without adding cost or complexity the inspection does not need.
- Help your team own the system.
- Installation is followed by testing against agreed requirements, operator and maintenance training, and documentation. We generally provide application source-code access so your team can maintain the delivered solution.
HOW WE HELP
A new system or an existing system that needs to be improved.
Whether you are starting from scratch or improving an existing installation, we begin with the inspection problem and work toward a practical solution.
Complete vision
Troubleshooting
& project recovery
Find the cause of unreliable inspection. We evaluate optics, illumination, camera selection, software, and controls before recommending what to keep or replace.
Talk through the problemRetrofits
& upgrades
Address obsolete equipment, changing parts, and new inspection requirements with a considered upgrade to your existing production environment.
Discuss an existing systemENGINEERING DEPTH
Quality inspection
starts before
the camera.
Quality starts with the image. We calculate camera resolution from the required inspection accuracy, then verify optics, illumination, field of view, exposure, and part presentation in our lab before proposing a solution.
INSPECTION
Flaw & defect detection
Flaw and defect detection is a core strength: surface defects, assembly verification, missing features, and print defects. We use predictable rule-based tools where practical and consider AI for difficult defect definitions or complex backgrounds.
MEASUREMENT
Precision in 2D & 3D
Precision 2D and 3D dimensional measurements with telecentric optics and custom illumination. Past 3D applications include transmission-plate defects, pipe-weld inspection, and steel-bar defects.
IDENTIFICATION
Read it. Verify it.
OCR, OCV, lot and date codes, label verification, and 1D/2D code reading, with attention to print quality and real production variation.
CONTINUOUS WEB INSPECTION
Line-scan expertise
Continuous web inspection using line-scan cameras is a major part of our work. We have integrated systems for continuous web materials, double-sided transmission plates, large silicone polishing pads, and cylindrical parts. We design imaging, lighting, motion, and triggering together around the application.
From pixels to PLC.
Vision programming is one part of the application. We work with PLCs, HMIs, industrial networks, and motion controls, including Allen-Bradley and Keyence controls. Cognex VisionPro and In-Sight spreadsheet programming, Keyence vision software, and custom interfaces help connect inspection to machine operation.
SELECTED WORK
Experience you
can see.
A selection of systems and inspection applications from our project work.
Battery Cell Inspection Station
MULTI-TECHNOLOGY INSPECTION
A multi-technology inspection station combining Keyence 3D profile scanning, Cognex line-scan cameras, and a Basler code reader.
- Inspection approach
- 3D profile data, line-scan imaging, and code reading brought together in a single station.
- Production integration
- Integrates into the customer's production line and statistics database, connecting inspection with production operation and reporting.
Browse the machine, part image, profile scanner, inspection display, and operating video.
Continuous Web Inspection
CONTINUOUS WEB INSPECTION
A line-scan camera mounted on a slide inspects the web for cracks. Imaging, illumination, and slide movement are coordinated to capture the material for inspection.
- Engineering focus
- Coordinate the line-scan camera, lighting, and slide movement to reveal cracks in the web.
- Experience
- Continuous web inspection is part of a broader line-scan specialty that also includes double-sided transmission plates, large silicone polishing pads, and cylindrical parts.
View the line-scan installation photo and operating video. Use the video controls to play the silent clip.
Automotive 3D Inspection Machine
AUTOMOTIVE / 3D INSPECTION
An automotive inspection machine built around the Keyence LJX 3D scanning head. The gallery shows the machine, full 3D inspection imagery, a color-mapped clutch disk, and its surface plot.
- Production integration
- Integrates into the customer's production line and statistics database, connecting inspection with production operation and reporting.
Syringe Print Inspection
PRINT VERIFICATION
Machine vision applied to printed features on medical products.
FROM SAMPLE TO STARTUP
Test the approach.
Then build the system.
We generally complete feasibility work before quoting. Good and defective samples, inspection specifications, and production requirements give the project a sound starting point.
Understand
Define the problem, inspect the production environment, and agree on inspection specifications. Obtain good and defective samples, defect definitions, tolerances, and production requirements.
Prove
Test imaging, optics, lighting, and part presentation in our lab. Where needed, use an engineering study to assess false accepts, false rejects, and performance before committing to production hardware.
Engineer
Develop the proposal around agreed specifications and a defined scope. After approval, source components, develop software, and test the planned solution before on-site installation.
Commission
Install, test against agreed requirements, train your team, and provide documentation and support for the delivered system.
A FOCUSED ENGINEERING PARTNER
Machine vision specialists.
Automation experience.
Vision Controls has delivered hundreds of machine vision projects for manufacturers and machine builders since 2002. Our experience spans automotive, food, electronics, consumer goods, medical, and agriculture applications. Approximately half of our customers return for additional projects.
We are based in the Chicago area, with projects completed across the United States and internationally. You work directly with an experienced engineering team, from the initial discussion through installation and support.
Start a conversationBEFORE WE TALK
Practical questions.
Straight answers.
Why work with a specialist vision integrator?
A camera is one component of the solution. We work through requirements, imaging, component selection, software, and the agreed controls integration, then help bring the application into production.
What should we provide for an evaluation?
Start with a description of the problem, good and defective sample parts, defect definitions, inspection tolerances, line speed, and installation constraints. Call or email first so we can discuss the right next step for your application.
Do you work with our preferred camera brand?
Our core platforms include Cognex and Keyence. We consider the existing equipment, inspection requirements, and feasibility results when recommending a platform. An existing hardware choice may need reassessment if it cannot meet the requirements.
Does every application need 3D vision or AI?
No. We start with the simplest practical approach. 2D imaging and rule-based tools are often appropriate; 3D or AI is considered when the inspection needs it and testing supports that choice.
How do you establish whether an inspection is feasible?
We generally complete feasibility work before quoting. We calculate the camera resolution needed for the inspection accuracy, then verify the lens, lighting, working distance, field of view, exposure, and part presentation with representative samples. For applications needing more extensive performance data, we can propose an engineering study.
Can you help when an existing vision system is unreliable?
Yes. We assess the inspection concept, optics, lighting, camera resolution, software, and integration to identify the cause. The recommendation may be an adjustment, an upgrade, or replacement of unsuitable hardware. The approach depends on the requirements, condition of the system, and a realistic project scope.
What happens after installation?
Training and documentation help your team operate and maintain the system. We generally provide access to the application source code. Remote support is available during office hours; other support arrangements can be discussed. Specific deliverables and responsibilities are defined by the project scope.
LET’S TALK ABOUT YOUR APPLICATION
What does your
system need to see?
A new project, an inspection challenge, or a system that is not performing as expected. Start with a call or email.
630-661-5601 PBiegunski@VisionControlsInc.com
Glen Ellyn, Illinois
Serving the Chicago area and projects beyond.
To get started: tell us about the part, the defect or measurement, and your production requirements.