Integrated Industrial Embedded Solutions

Improving Machine Value through Collaborative Engineering

At ViE, we believe that a project’s completion is just the beginning of the journey. We don’t just build machines; we build long-term competitive advantages for our clients. Today, we are excited to highlight our ongoing collaboration with AFA, a leader in the glove manufacturing space.

The Challenge: Balancing Performance with Value
AFA’s existing glove production lines have long been benchmarks for reliability. However, in today’s rapidly changing market, AFA sought to optimise their hardware footprint to ensure they remain the most competitive choice for their own end-users.

The goal was clear: Maintain the high-performance standards AFA is known for, while re-engineering the system for maximum cost efficiency and streamlined assembly.

The Solution: A Collaborative "Design for Value" Initiative
In response to AFA’s vision for a more competitive, accessible machine, our engineering teams launched a joint "Design for Value" initiative. AFA challenged us to leverage our deep technical knowledge of the existing system to find new efficiencies—without compromising the world-class performance their brand is built on.

• Customer-Centric Optimisation: Guided by AFA’s market insights, we integrated the latest components to reduce system complexity while maintaining high-speed output.
• Streamlined Manufacturing: In direct response to the need for a leaner footprint, we redesigned the framework to minimise material redundancy and significantly shorten assembly lead times.
• Future-Proofing: We integrated File over EtherCAT (FoE) protocols, allowing for seamless data transfer and firmware updates directly over the network. This eliminates hardware bottlenecks and makes the system significantly easier to maintain and update in the field.

Why This Matters for AFA Customers

This initiative reinforces AFA’s position as the most competitive choice in the industry. Through this ongoing collaboration, we ensure their machines remain:

1. Economically Superior: Higher ROI through smarter engineering.
2. Technologically Current: Built with the latest industry-standard components.
3. Reliably Robust: The same "battle-tested" durability AFA is famous for, now in a more efficient package.

A Word from Our Partner

Chester, CEO of AFA Technologies

“At AFA Technologies, we continuously look for solutions that improve machine efficiency, reduce system complexity, and deliver long-term value to our customers.

ViE Technologies has provided us with a new pressure sensor integrated with an IO controller card that clearly stands out from our previous solution. The significantly smaller footprint allows for a more compact control panel design, while achieving meaningful cost savings without compromising performance or reliability.

The inclusion of an EtherCAT communication port has been a major advantage. It has improved installation efficiency and provided better diagnostics and troubleshooting capabilities during commissioning and operation. This has helped our engineering and service teams work more effectively and reduce overall system downtime.

We appreciate ViE Technologies’ strong technical support and practical engineering approach in delivering a solution that aligns well with our automation requirements. We see this as a successful collaboration and look forward to further opportunities to work together on future machine developments.”

Driving Semiconductor Innovation: Edelteq’s Positive Experience with ViE Technologies

Incorporated in 2004, Edelteq is a leading semiconductor manufacturing solutions provider, offering a wide range of products and services for the semiconductor industry. Specializing in engineering support for semiconductor equipment and materials used in IC assembly and test processes, Edelteq has built a strong reputation for delivering innovative and reliable solutions.

Edelteq has expressed high satisfaction with ViE Technologies' VINET I/O solutions and lighting controllers. According to an Edelteq engineer, ViE’s I/O cards are exceptionally easy to implement, facilitating a seamless integration process with minimal disruption. The competitive pricing of the I/O solutions adds further value, making them a cost-effective choice for automation needs.

A standout feature is ViE’s LSC-G2 lighting controller, which enables software-based control of multiple light channels, significantly reducing inspection times and boosting operational efficiency.

Edelteq also complimented ViE Technologies for their short lead times and excellent technical support. ViE team is recognized for being highly responsive, attentive, and committed to addressing customer needs. With a seamless blend of user-friendliness, reliability, competitive pricing across its product portfolio, and outstanding customer service, Edelteq confidently recommends ViE Technologies' I/O solutions and lighting controllers to businesses seeking dependable and efficient automation solutions.

Sophic Automation Testimony: Smooth Integration of VisionXpert Smart Code Reader with Outstanding Service and Support from ViE Technologies and NSCB

Sophic Automation has successfully integrated the VisionXpert XS-90 Smart Code Reader with outstanding service and support from ViE Technologies and great collaboration with our trusted sales channel partner, NSCB System. From initial consultation to on-site implementation, ViE’s professionalism and technical expertise were evident at every step. The ViE team worked closely with Sophic to provide expert guidance, answer all inquiries promptly and minimise any potential downtime. This level of service made the integration process both seamless and effective.

The integration also marks a significant milestone as Sophic moves toward greater automation and efficiency. The XS-90 is a user-friendly smart code reader designed to automate code scanning, streamline operations and increase overall productivity. Its high-speed scanning capabilities and advanced features have greatly improved operational efficiency, delivering precise and reliable code reading performance in a fast-paced manufacturing environment.

Smart Code Reader (XS-90) Key benefits:

• High-speed, automated scanning for streamlined production
• Simple integration with existing systems
• Reliable performance in challenging manufacturing conditions

“We’ve experienced significant improvements in efficiency since incorporating the XS-90 into our production line,” said Management at Sophic Automation. “The support we received throughout the integration process was outstanding and made a significant difference in how smoothly everything was implemented.”

ViTrox Technologies Successfully Integrates ViE Technologies’ Latest Innovation– VisionXpert Solution XS-95 Smart Code Reader– for Enhanced Semiconductor Manufacturing

ViTrox, committed to being the World’s Most Trusted Technology Company and the leading solutions provider for the electronics industry, has successfully integrated ViE Technologies’ latest innovation, the XS-95 Smart Code Reader, into its Automatic Nozzle Changer (ANC) Solutions.

The VisionXpert Solution XS-95 Smart Code Reader, with its compact dimensions of 25mm (H) x 46mm (L) x 38mm (W), offers the flexibility to be mounted in small and constrained areas. ViTrox seamlessly incorporated the XS-95 into the ANC module without altering its manufacturing design. Additionally, the XS-95 delivers consistent decoding performance under stringent manufacturing conditions.

Key benefits of the XS-95 include:

1. High-speed and high-quality image acquisition.
2. Compactdesign and flexible adaptation suitable for various mounting environments.
3. Resilience and reliability in challenging industrial application environments.
4. Advanced code reading algorithm for optimal performance.

"We have observed significant enhancements in operational efficiency and reliability since adopting the XS-95," states Davin Tan, Senior Mechanical Engineer from ViTrox Technologies's Machine Vision System Business Division. "Its compact design and precise decoding capabilities have proven instrumental in overcoming previous challenges, setting a new standard for our semiconductor manufacturing processes."

AFA Experiences Pleasant Collaboration with ViE Technolgies

AFA Technologies Sdn Bhd, incorporated in Year 2002 is primarily an automated equipment designer and manufacturer, focusing in serving glove packaging industries, medical products or device packaging and food packaging industries. Over the years of continuous development of products, AFA has become an important partner to many local and international glove manufacturers as well as medical and food packaging industries.

In year 2009, ViE has started to approach AFA by sharing their vast experience and proven capabilities in integrating their solutions with similar industries in the Northern Region of Malaysia.

AFA was impressed with ViE's and the very first collaboration project was machine model LTM 72 integrated with ViE's customized solutions. The latest project is the 4th version of LTM 72 embedded with multiple enhancements and new features, after years of continuous in-house and on field testing and improvement.

Besides, price competitiveness and willingness to make continuous improvement in terms of product and service quality have further strengthening the business partnership between AFA and ViE. ViE even goes the extra miles to enhance its existing solutions by considering the customer's feedback. AFA has witnessed that ViE has consistently upheld its strong business ethnic and core values (Integrity • Accountability • Courage • Trust & Respect. Gratitude & Care) throughout the process of dealing with customers, and this marks a significant move toward securing the strong partnership between ViE and AFA for the past 7 years.

Chester Tan, Senior Manager of AFA, said, “Overall, I will say we have a great experience working with ViE team. If I would use a phrase to describe our relationship, I will use a Chinese Proverb to describe it “细水长流”, which means good partnership in a steady and long-term basis.”

As a top EMS company, AFA believes that ViE delivers the quality it needs. AFA will be delighted to refer ViE for any potential business collaboration whereby it is a trust worthy and reliable partner to work along with.

High-Mix Low-Volume (HMLV) Quality Assurance for PCB Assemblies

1. Executive Summary

This application note details the implementation of a high-resolution smart camera system designed for High-Mix, Low-Volume (HMLV) PCB inspection. The solution addresses the challenge of balancing a wide Field of View (FOV)—necessary for full-panel coverage—with the granular resolution required to detect minute structural defects across seven distinct PCB variants. By utilising an integrated edge-processing architecture, the system successfully identifies LED structural integrity (cracks/dents) and connector presence.

2. Hardware Specifications

The inspection utilises the VisionXpert XC-130 Smart Camera, a standalone unit capable of edge-based image processing.

3. System Architecture and Connectivity

The XC-130 is designed for seamless integration into industrial environments, supporting multiple communication protocols for data logging and PLC handshaking:

• Edge Processing: All image analysis and algorithm execution occur locally on the camera's internal processor.
• Power Efficiency: The system operates on 24VDC with a low 6W power draw, suitable for integration into existing SMT lines.
• Protocol Flexibility: Results and images are pushed via FTP or TCP/UDP, allowing for real-time data logging.

4. Implementation Workflow

To overcome the limitations of large-area inspection, the workflow utilises the same camera model deployed at two distinct working distances to achieve specific quality goals:

4.1 Macro-Level Deployment (Full Panel Inspection)

• Setup: Positioned at a working distance of 310mm – 380mm.
• Capability: Optimises the FOV for full-panel captures (up to 398mm x 335mm), ideal for high-speed presence/absence and connector counts.

4.2 Micro-Level Deployment (Precision Defect Detection)

• Setup: Positioned at a working distance of 55mm – 135mm.
• Result: Concentrates the full 5MP camera onto a tighter area (as small as 57mm x 48mm), significantly increasing the pixels-per-millimetre. This enables the Contour Count tool to resolve cracked LED caps and dents that are physically too small.

5. Integrated Smart Lighting

A standout capability of the XC-130 is the ability to modulate its internal lighting and to reveal defects hidden by glare or low contrast.

• Polarised Contrast Enhancement: By utilising the Integrated White Polarised light source, the system effectively mitigates glare from reflective solder and metallic surfaces. This is critical for the Contour Count tool to distinguish between a healthy LED cap and one with structural cracks.
• Diffuse Illumination: For boards requiring softer, more even lighting to avoid harsh shadows on complex components, the system can switch to a Diffuse lighting mode.
• Advanced Sensitivity Tuning: To maintain high accuracy on low-reflectivity substrates (such as black solder masks), the system allows for independent adjustment of Gain and Gamma.
• Strobe Synchronisation: The lighting is managed through a Strobe Mode across Top, Middle, and Bottom LED segments, ensuring perfectly timed illumination for every capture to prevent image wash-out.

6. Conclusion

The XC-130 provides a versatile inspection gate for high-mix PCB assemblies. By adjusting the working distance and utilising integrated smart lighting, a single camera model can perform both high-level panel verification and micro-level integrity checks. This flexibility ensures that manufacturers can detect safety-critical structural defects and missing micro-components without increasing station complexity.

Integrated Quality Assurance and Intelligent Process Routing

1. Problem Statement

In high-volume manufacturing, "defect leakage" occurs when faulty products continue through the assembly line instead of being stopped immediately. This happens because inspection systems often operate in isolation, lacking the real-time data integration needed to trigger automated stops.

As a result, companies waste time and expensive resources testing units that are already defective, driving up operational costs. Without a unified system connecting vision inspection to the wider factory, manufacturers suffer from poor traceability and cannot reliably prevent bad units from entering high-value downstream processes.

2. Solution

Our solution eliminates defect leakage by integrating ViTrox VisionXpert Smart Cameras for real-time, automated inspection. Paired with V-ONE MARS IOT Device and V-Trace Manufacturing Intelligence (Software), it ensures full traceability and automated interlocking. This unified system prevents faulty units from reaching downstream stations, reducing waste and optimizing high-volume production efficiency.

2.1 VisionXpert Smart Camera, XC-130

The VisionXpert XC-130 is a compact "mini-AOI" solution designed to complement full-scale AOI systems by providing high-resolution inspection in tight assembly cells where standard AOI machines cannot be integrated.

2.2 V-ONE MARS Edge Gateway

V-ONE MARS serves as the protocol bridge and automation hub, enabling seamless communication between the vision sensor and the broader factory ecosystem.

3. System Architecture and Connectivity

The system uses a tiered architecture to ensure deterministic control and enterprise-level data availability:

1. Sensing/Detection Layer (XC-130 Smart Camera): Performs real-time inspection of fasteners, bolts, and barcodes using deep learning algorithms to maintain stability on reflective industrial surfaces.

2. Intelligence Layer (V-ONE MARS Gateway): Acts as a "Protocol Bridge," receiving native data (TCP/IP & FTP) from the camera and translating it into the required format for the downstream test station PLCs or enterprise systems.

3. Traceability Layer (V-Trace): The central repository for inspection results, high-resolution images, and reports. V-Trace manages the "digital thread," linking serial numbers to specific vision results.

4. Implementation Workflow: Automated Interlocking

4.1 Step 1: Barcode-Based Recipe Call-Up

To support high-mix production, the operator identifies the unit and selects the matching inspection template (e.g., specific bolt patterns) from the V-Trace software. This ensures the correct inspection logic is applied to the specific unit before the process begins.

4.2 Step 2: The "No Good" (NG) Signal Export

Upon completing the inspection, the camera generates a result packet:

• Method: The camera uses its native FTP client to push a result file (txt) to a dedicated directory on the V-ONE MARS’s FTP server.
• V-ONE MARS tidy up data and upload to VTrace Server.
• Data Content: The packet includes the Barcode ID, Global Pass/NG status, and ROI Mapping for each item inspected.

4.3 Step 3: Downstream Interlock (Test Station)

When a unit reaches the subsequent test station:

1. The station's Smart Camera XC-130 passes a signal to V-ONE MARS to query from VTrace Server for the result file matching that unit's ID.

2. If V-Trace has flagged the unit as "NG", V-ONE MARS sends a "Bypass" signal via Modbus TCP to the station.

3. The test cycle is inhibited for the unit, preventing defective units from entering downstream processes, saving test time and protecting costly test fixtures.

5. Traceability and Repair Management

The integration of V-Trace ensures that every defect is actionable. The primary objective is to pinpoint specific failure locations, allowing for surgical repairs and minimal rework time.

• OI Mapping: By utilizing Region of Interest Mapping, V-Trace enables users to identify the failure area coordinates for the repair station.
• SPC Tracking: V-Trace pairs with VONE Visualization Analytic to aggregate individual ROI Mapping data to generate Statistical Process Control (SPC) reports, helping managers identify if a specific assembly tool or robotic cell is trending toward failure.

6. Conclusion

Integrating the Smart Camera XC-130 with the V-ONE MARS Gateway and V-Trace software creates an intelligent, interlocked production environment. This solution eliminates the waste associated with unnecessary re-testing and provides the granular data required for true Industry 5.0 smart manufacturing.

High-Speed Connector Inspection with VisionXpert Smart Camera

Background

A global electronics component manufacturer aimed to enhance its final quality inspection process for a high-precision connector. The inspection required verifying that four contact pins were present and properly seated, as well as confirming the presence and correct alignment of two plates, one on each side of the connector. Previously, these checks were performed manually under magnification. While effective at low volumes, manual inspection became a bottleneck as production increased. Operators struggled to maintain consistency at higher speeds, which led to missed defects, slower throughput, and rising labour costs.

Challenges

The primary challenges included human fatigue and inconsistency during repetitive visual checks, the risk of overlooking subtle misalignments or missing components, throughput limitations with manual cycle times averaging two to three seconds per connector, and the absence of automated traceability for quality assurance and compliance purposes.

To address these issues, the manufacturer integrated the VisionXpert Smart Camera directly into the production line, replacing the manual inspection station. Configured with AI-powered vision tools, including pattern existence detection and precision counting, the system instantly confirmed the presence of all four pins and validated the position of the two plates on either side. Any missing, misaligned, or incorrectly positioned parts were flagged in real time, and each inspection result was logged with image evidence to ensure full traceability. Operating inline with the conveyor, VisionXpert enabled a continuous, hands-free inspection process that maintained accuracy while keeping pace with production demands.

Results

In internal testing with similar connector types, average inspection time improved from two to three seconds per unit to just 0.1 seconds, a speed increase of 20–30× compared to manual checks. This allowed significantly higher throughput without creating production bottlenecks. Defect detection remained consistent and fatigue-free across all operating hours. Such performance typically enables a return on investment in less than three months, driven by higher output, reduced rework, and fewer quality escapes. In addition, the system captured and stored every inspection, providing full traceability for audits and compliance.

Conclusion

By replacing manual inspection with VisionXpert Smart Camera, the manufacturer eliminated a critical bottleneck while ensuring 100% component verification. With its rapid inspection time, real-time defect detection, and complete traceability, VisionXpert transformed quality control from a labour-intensive task into an automated, high-speed safeguard, delivering measurable improvements in productivity and return on investment.

High-Performance Hardware for Industrial Automation: Exploring ViTrox's ECS Solutions

When building complex automated machinery, the reliability of the entire system often comes down to its core embedded components. ViTrox’s ECS Business Unit specializes in exactly this—designing and manufacturing the critical hardware that Original Equipment Manufacturers (OEMs) and System Integrators rely on to drive their automated lines.

The ECS division operates through two distinct product families: Integrated Industrial Embedded Solutions (IIES), which handles the core control and communication infrastructure, and VisionXpert, which provides edge-level inspection and traceability.

Integrated Industrial Embedded Solutions (IIES)

The IIES portfolio provides the hardware architecture necessary for reliable machine communication, precise motion, and vision lighting. It is built specifically for the realities of the factory floor, where electrical noise and continuous 24/7 operation are the standard.

Industrial I/O and Motion Control Cards: These components manage the high-speed responsiveness of the machinery. To maintain signal integrity in industrial environments, the cards feature high isolation voltage (up to 3750 Vrms). This level of isolation actively protects against electrical noise, significantly reducing the likelihood of false hardware triggers and keeping machinery running consistently.

Illumination Controllers and Light Sources: Consistent, highly controlled lighting is required for any machine vision system to function properly. The ViLIGHT Digital Dimming Series and controllers like the iL3K28-U3 provide precise analog brightness adjustments.

• Intelligent Channel Grouping: This feature allows a single trigger signal to sync multiple output channels, coordinating complex, multi-angle light sources with minimal latency.
• Hardware Protection: Built-in programmable noise filtering and automatic overheating safeguards cut analog outputs during signal failures, helping to protect both the controller and the LED setups.
• Software Integration: Lighting environments can be configured easily via standard USB using the VIPRO-LIGHT software or embedded directly into custom applications using the VTLightDLL function library.

VisionXpert: Intelligent Edge Inspection

As production lines require faster, decentralized decision-making, the VisionXpert line brings smart inspection and code reading directly to the edge of the network.

XpertScanner (XS-Series) Smart Code Readers: Tailored for environments like PCB manufacturing and warehousing logistics, these scanners are designed to be highly adaptable. The XS-95, for instance, measures just 25mm x 46mm x 38mm, allowing it to fit into tight machine modules without requiring structural redesigns. Models like the XS-100 and XS-200 utilize deep learning algorithms to decode 2D codes and barcodes, even on degraded, warped, or reflective surfaces. For more standard scanning needs, the XS-90 provides a cost-effective alternative.

VisionXpert Smart Cameras (XC-Series): These palm-sized, industrial-grade cameras (featuring up to 5MP in the XC-100 Series) are designed to automate localized visual checks. In practical electronics manufacturing applications, these cameras have been shown to reduce manual inspection cycle times from several seconds down to roughly 0.1 seconds per unit. Utilizing AI-based vision tools, they quickly verify component presence, count pins, and check for subtle misalignments, reducing human fatigue and minimizing quality escapes.

Building with ViTrox ECS

Whether you are an OEM designing a new semiconductor handler or an integrator optimizing an existing SMT assembly line, the ECS Business Unit provides the foundational hardware for the job. By combining the stable machine control of IIES with the localized intelligence of VisionXpert, manufacturers can reduce labor dependency, improve overall line throughput, and maintain high standards of quality control.