The companies said they worked with image processing specialist Sightwise to develop the system. SMS group’s digitalized solution, iForge, enables fully automatic testing for both surface defects and geometrical deviations. 

“This collaborative partnership allows us to integrate state-of-the-art testing technology into the production process and thus solidify our standards on a lasting basis,” said Thomas Baur, senior production manager at Hirschvogel. 

The solution has a platform which trains analysis models with synthetic data using CAD data or 3D models to make an analysis model within 6–8 hours. Material properties and surface textures are digitally simulated to reflect actual conditions while an automated process generates photorealistic image data and applies multiple types of defects to the components. 

“The new system enables us to speed up the final inspection significantly and ensure maximum process stability in the line itself,” said Axel Rossbach, forging technology expert at SMS group. 

Hirschvogel said its inspection process has a fully automated feeding system and high-resolution cameras. The system can find geometry deviations and surface defects while allocating them to the digital defect catalog. This makes it so accidental disposal of good parts is almost completely avoided.