Error-free laser marking with the AOI vision system

The AOI Vision System is used for automated object recognition, precise alignment, and quality control in laser marking. It recognizes components based on contours, edges, or features, precisely aligns the marking, and checks the result immediately after the marking process. This prevents errors, reduces scrap, and makes processes safer and more efficient. The AOI Vision System helps manufacturers achieve consistently high product quality and reliably meet the demands of challenging manufacturing environments.

The difference lies primarily in the design and image size. With the internal AOI vision system, the camera is integrated directly into the laser head and is particularly suitable for small components with high precision requirements. The external AOI vision system uses a separate camera unit and allows for larger image sizes and greater flexibility for varied or complex components.

An internal AOI vision system is particularly suitable when small components need to be processed with high accuracy or when installation space is limited. An external AOI vision system is usually the better choice when larger image sizes, more complex geometries, or a high degree of variety are involved in the process.

The achievable resolution depends on the AOI variant and the image size. The internal AOI vision system achieves resolutions of 10 µm/pixel with an image size of 9 × 9 mm². Depending on the image size, the external AOI vision system achieves resolutions of 20 to 80 µm/pixel with image sizes ranging from 20 × 20 to 110 × 110 mm².

Compared to manual inspection, the AOI vision system significantly reduces the error rate. Manual visual inspections are prone to errors, time-consuming, and hardly reliable when it comes to small or difficult-to-read markings. AOI performs this step automatically—regardless of location, position, or component variety. This reduces scrap, avoids rework, and relieves the burden on skilled personnel.

The AOI vision system is optimized for a wide range of codes and characters. It reliably reads both 1D barcodes and 2D codes such as DataMatrix or QR codes. In addition, integrated OCR character recognition is available to check alphanumeric texts and serial numbers directly in the process. This makes AOI suitable for almost all common types of marking in industrial manufacturing – from component numbers and batch codes to safety-related markings.

The AOI Vision System can manage up to 500 different part types. Each type can be stored with specific parameters such as geometry, tolerance, alignment, and camera resolution. This is particularly useful in production environments with a high degree of variety, e.g., when many different components or product series are processed on one line. Switching between types is software-supported and does not require manual retooling.

Yes, the AOI Vision system requires both the optional AOI plugin and a hardware module (camera unit). The plugin is fully integrated into the ACI marking software Magic Mark, allowing image processing, position detection, and quality control to be controlled centrally via a single interface—without the need for additional programs or interfaces. The hardware module must either already be installed on the laser head or can be retrofitted.

Note: Magic Mark V3 build 500 or higher is required to use the AOI plugin.

The AOI Vision System can be integrated into the ACI Magic Mark marking software as an optional plug-in and is compatible with all ACI infrared laser systems, such as the laser systems in the following series: Business Fiber USP, Business Fiber, Economy Fiber, Business Diode IR, Economy Diode, and Business CO₂. In addition to the camera unit, Magic Mark V3 software build 500 or higher is required for retrofitting. The laser station must also have enough physical space for the camera unit. This means that AOI can be integrated into many existing systems without the need for a complete replacement.

Yes, the AOI Vision system can be retrofitted to many existing ACI laser stations. The retrofit includes both the camera unit and the AOI plugin, which is integrated directly into the Magic Mark marking software. A Magic Mark V3 build 500 or higher is required. This allows image processing, position detection, and quality control to be performed centrally via a common user interface—without the need for additional external software or interfaces. Implementation is straightforward and does not require extensive adjustments to the production environment. Companies can thus take advantage of automatic object recognition and quality control even retroactively, without having to invest in completely new laser systems.