In modern aircraft production, precision is everything. Every hole and every fixing point must be precisely positioned to ensure safety and quality. As part of the DiCADeMA project (Digital Cabin Architectures and Design for Manufacturing) led by the German Aerospace Centre (DLR), a novel, fully digitally networked process has been developed.

Through intelligent automation, this approach elevates aircraft cabin manufacturing to a new level. A key component in this process is an Ensenso 3D camera from IDS Imaging Development Systems, which ensures highly precise detection and alignment of drilling positions.

Digital process chain from design to production

The aim of the project is to establish a continuous digital thread from design to production. Changes to the cabin design, such as seat spacing and the associated new position of the luggage compartments, are recorded directly in the digital design data and automatically transferred to production planning. Simulations allow these variants to be validated before any physical component is manufactured. Once digital validation is complete, production can begin immediately.

To make this digital process tangible, an automated system for marking drilling positions was developed on a mock-up of an aircraft frame structure. Several networked systems work together in this setup: An autonomous mobile robot (AMR) approaches the frame and positions itself near the target area. Mounted on the AMR is a lightweight robot that moves the marking unit, including the 3D camera, into the acquisition position. At this point, the Ensenso camera takes over the fine alignment. An integrated Manufacturing Execution System (MES) controls all sub-processes.

The role of the 3D camera

The camera used, an Ensenso N36, captures the environment as a three-dimensional point cloud and matches it against the CAD data of the aircraft frame. In this way, even the smallest deviations between the target model and the actual geometry can be detected. The system uses this data to calculate precise correction values, which are transmitted to the higher-level MES.

Communication takes place via a standardised OPC UA interface, ensuring reliable and secure data exchange between the camera, the robot and the control system. The MES translates the acquired data into concrete control commands for the robot, which then performs the marking of the drilling position.

The autonomous robot achieves a positioning accuracy of around five millimetres. This allows the camera to reach the acquisition position without risk of collision.

The Ensenso camera becomes a key link between digital design and real-world manufacturing: It recognises local geometries, in this case several rivets and the surface on which they are set and compares the captured point clouds with the reference data from the CAD. This comparison is made possible, among other things, by hand–eye calibration and an iterative minimisation process. The result is a transformation matrix that precisely describes the correction required for the drilling position. By applying this correction value, the drilling position can be set precisely.

An operator follows the vehicle and drills the hole immediately afterwards at the marked spot. This process is repeated for each installation point, while robots and humans can work safely in close proximity to one another.

For this application in aircraft manufacturing, a compact camera with a very short working distance is required in order to keep the path from the acquisition position to the drilling position as short as possible. This helps to maintain high accuracy and avoids excessive robot movements. The Ensenso N36 meets these requirements. The Ensenso N series has been specially developed for use in demanding environmental conditions.

Thanks to its compact design, the camera can be installed in a space-saving manner, either in a fixed position or mounted on a robot arm. This makes it equally suitable for 3D capture of both moving and stationary objects. The integrated projector ensures high-contrast texture even under challenging lighting conditions: It projects additional structures onto the object surface using a pattern mask with a random dot pattern, thereby supplementing missing or weak features. All cameras are pre-calibrated at the factory and can therefore be put into operation quickly and easily.

Benefits for manufacturing

The digital process offers the DLR several advantages. Camera-based alignment significantly increases precision and repeatability. At the same time, continuous data acquisition enables complete documentation and traceability of all process steps. Assembly personnel are relieved, as the robot takes over the time-consuming task of position determination, allowing skilled workers to focus on the actual assembly operation. In addition, production times are significantly reduced, as manual measurements or readjustments are no longer necessary.

The demonstration on the mock-up clearly illustrates the potential that lies in combining the digital process chain, robotics and 3D image processing. In further project steps, the accuracy of the system and the performance of the evaluation algorithms will be examined in greater detail. This will involve not only the camera itself, but also the optimisation of the mathematical methods used to align nominal and actual point clouds.

What is currently being tested in aircraft manufacturing may also be applied in other industries in the future. The system impressively demonstrates how optical sensor technology and intelligent software are paving the way for a new era in manufacturing: networked, efficient and precisely on target.

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This makes it suitable for applications such as logistics, automation and robotics, where precise 3D data is required at real-world process speeds.

The Nion captures moving objects with virtually no blurring. Its high resistance to stray light ensures reproducible measurement results both indoors and outdoors. The measuring range of 0.3 to 7.5 metres covers typical industrial scenarios. The robust IP67-rated housing allows it to be used in more demanding environments. Power over Ethernet (PoE) reduces installation effort and cabling.

Patrick Schick, Product Manager for 3DVision and Imaging Software at IDS, says: “The Nion provides stable depth data even under variable lighting conditions. This provides a solid foundation for automation processes that rely on fast and accurate 3D data.”

Compared to standard ToF cameras on the market, the onsemi AR0130 depth sensor offers higher resolution, lower noise, more stable results in ambient light and improved motion stability. This enables the Nion to achieve high depth accuracy even when objects are moving quickly and under variable lighting conditions.

Thanks to its compact design, high measurement quality and excellent value for money, the Nion offers a straightforward introduction to 3D image processing. Companies can integrate the camera flexibly into existing systems and benefit from a cost-effective solution for reliable depth data. “In many cases, existing 2D processes can be retained and supplemented with depth data where necessary, if this aids decision-making within the process,” emphasises Patrick Schick.

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At Machine Building Live, IDS highlighted everything from open modules to fully embedded inspection systems, with a live demonstration of object detection using AI. Also on show was a live streaming camera for use within a machine to record faults and events, which can be downloaded subsequently for analysis.

A further demonstration highlighted IDS’ capability in 3D imaging for applications such as robot pick and place, as well as in the medical industry in areas such as MRI scanners.

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uEye Live: Streaming, monitoring and event recording

The highlight at the IDS booth is the new uEye Live Monitoring camera series, which has been specially developed for live streaming and continuous process monitoring. These compact industrial cameras work with state-of-the-art SoC components from IDS technology partner Ambarella, offer a particularly high resolution and enable event-based recording directly in the camera memory. They solve monitoring tasks entirely without an additional PC and are therefore recommended as an uncomplicated and quickly integrated camera solution for visualising machine processes without any programming effort.

uEye EVS: Less data, more speed, maximum precision

Event-based imaging is one of the most ground-breaking innovations in the field of machine vision since the advent of artificial intelligence. It enables the efficient optical detection of movements with almost seamless temporal resolution. IDS will be showcasing the new uEye EVS with the Sony Prophesee IMX636 event-based vision sensor at automatica. Unlike conventional industrial cameras, it only captures changes in the image – each individual pixel acts like a highly sensitive motion detector. This produces razor-sharp images of high-speed processes while minimising the data load.

uEye 3D: IDS’ first Time-of-Flight 3D camera

The new, cost-effective uEye 3D iToF camera from IDS uses the 1.2 MP onsemi sensor and integrated depth processing to generate precise 3D data in real time. With a high frame rate and strong ambient light suppression, sharp images are created without motion blur – even with fast movements and direct sunlight outdoors.

“Our perfectly harmonised hardware and software solutions enable the particularly fast, flexible and efficient use of industrial image processing. With the new uEye Live Monitoring cameras, users can keep an eye on their processes at all times,” says Alexander Klingner, Head of Product and Project Management at IDS. “These and other innovations that we are presenting at automatica are setting new standards for what is possible in automation. They open up new and exciting markets and applications for IDS and our customers.”

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In general, companies in the machine vision industry faced several challenges in 2024. According to the VDMA Machine Vision department, a nominal 10 per cent decline in sales was forecast for the German machine vision industry compared to the previous year.

No change in trend is expected for 2025 either. This development is mainly attributed to falling demand from the manufacturing industry. Nevertheless, there are opportunities in new sales areas such as logistics, medical technology and intelligent transport systems. IDS is expanding its portfolio accordingly.

“The past year has brought its challenges, but we have used this time to regroup and work on some exciting projects,” explains Jan Hartmann, Managing Partner at IDS. Throughout 2025, the company plans to successively launch innovations on the market.

The first models of the uEye Live camera series for live streaming, industrial process monitoring and recording video sequences in the camera memory are already available to order. This will be followed by event-based cameras for highly efficient motion analyses. The compact models visualise even extremely fast movements completely loss-free. At the same time, they ensure a significantly reduced amount of data compared to conventional, image-based camera technology – completely new possibilities for industrial and non-industrial applications. IDS will also supplement its 3D portfolio with a time-of-flight camera developed in-house

Tailor-made solutions

The company also focuses on client-specific developments. Customised special models are created according to individual requirements. The product spectrum ranges from customised designs and special software adaptations to modular solutions based on the building block principle. An experienced engineering team supports customers throughout the entire implementation process.

IDS combines tradition and innovation: Proven values such as the ease of use of the products are just as much a part of the development work as the latest technologies. Investments at the headquarters in Obersulm, such as an in-house EMC measuring cabin, secure the production and development site. The company is also continuously exploring new markets, including India, which is considered a particularly interesting growth market.

Responsibility, innovation and networking

As a family business, the medium-sized company is also committed to its social responsibility and is involved in social and ecological projects in the region over and above its economic interests. This sense of responsibility shapes both the company’s actions and its long-term corporate strategy.

IDS is also investing in the expansion of a dynamic ecosystem and cooperating closely with start-ups. As a leading industrial camera manufacturer and image processing company, the corporate philosophy is to promote innovation. It makes its technology available for research purposes and new ideas, shares knowledge in working groups and supports educational institutions.

That the headquarters is situated in the AI region Heilbronn offers ideal conditions for this. IDS is part of an up-and-coming community for artificial intelligence and is actively involved in numerous supra-regional partnerships.

The company has an extensive network that drives innovation and helps shape the future of image processing, as Jan Hartmann confirms: “There are still uncertainties in the market, but I am confident that with our continued focus on development, innovation and the strength of our great team and partners, we are well equipped for the future.”

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IDS will be taking part at SPS for the first time, focusing on industrial image processing for robotics, process automation and networked systems. Philipp Ohl, Head of Product Management at IDS, explains: “Automation and cameras go together like a lock and key. Depending on the task, very different qualities are required – such as particularly high-resolution images, remarkably fast cameras or models with integrated intelligence.”

Consequently, the products and demo systems that the company will be showcasing at SPS are highly diverse.

The highlights of IDS can be divided into three categories: 2D, 3D and AI-based image processing. The company will be presenting uEye Live, a newly developed product line. These industrial-grade monitoring cameras enable live streaming and are designed for the continuous monitoring and documentation of processes. IDS will also be introducing a new event-based sensor that is recommended for motion analyses or high-speed counting. It enables the efficient detection of rapid changes through continuous pixel-by-pixel detection instead of the usual sequential image-by-image analysis.

In the 3D cameras product segment, IDS will be demonstrating the advantages of the new stereo vision camera Ensenso B for precise close-range picking tasks as well as a prototype of the first time-of-flight camera developed entirely in-house. Anyone interested in robust character recognition will also find what they are looking for at the trade fair stand: Thanks to DENKnet OCR, texts and symbols on surfaces can be reliably identified and processed. IDS will be exhibiting at SPS, stand 6-360.

Thanks to its high depth of field, it is able to capture objects over a large area and to localize all parts in a container at once, for example. This optimises the pick-and-place process and facilitates emptying of containers. The stereo vision camera is now available in series production.

The great strength of Ensenso B lies in the very precise detection of objects at close range. It provides a wide field of view and a high depth of field. More specifically, this means that the area in which an object is sharply imaged is unusually large. At a distance of 30 centimetres between the camera and the object, the Z-accuracy is approximately 0.1 millimetres. The maximum working distance is 2 metres.

The housing, which accommodates two 5 MP colour cameras from IDS, a pattern projector and all the electronics, is completely enclosed. This simplifies the cabling. Ensenso B complies with protection class IP65/67, which is an advantage in demanding operating conditions. With dimensions of just 120 x 56 x 104 millimetres, the new 3D camera’s design is also very space-saving. This makes it ideal for use on a robot arm, for example.

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According to the German Parcel and Express Logistics Association, 4.15 billion courier, express and parcel shipments were sent in Germany alone in 2022. Annual shipment growth to around 4.9 billion is realistic by 2027. Against this backdrop and the generally prevailing shortage of personnel, there is only one solution for shipping and logistics companies to cope with this immense volume of orders: increased automation.

The global robotic integrator AWL offers RODE, an intelligent robotic depalletiser solution. One of the locations where RODE adds value is for DHL eCommerce in Rotterdam. In this machine, two Ensenso 3D cameras from IDS are implemented to provide the required image data.

The intelligent robot-supported depalletiser, therefore, automatically destacks any packaged goods such as cartons, bags or containers from pallets and thus ensures their continuous processing – without delays or downtime. Even ‘extra shifts’ at peak times can be implemented at any time, for example to cope with the increased workload during Christmas. This frees up staff for more qualified tasks, such as the subsequent processing of consignments or handling customer inquiries. At the same time, it relieves employees of physically and ergonomically demanding tasks and reduces the risk of injury.

Up to 800 packages in continuous operation

At DHL eCommerce in Rotterdam, RODE processes up to 800 parcels per hour with a maximum weight of 31.5 kg each and places them on the corresponding sorting belt. The particular difficulty here lies in the robot’s picking of parcels of different sizes and weights. It must independently recognise the position of the objects in three-dimensional space and decide which package to pick next. It then has to determine the best gripping position and avoid collision with other parcels or the machine.

“This intelligent robotic solution integrates AI image processing and high-tech gripper technology. The system recognises products and can flip the items to ensure that the required long side is leading,” explains Sander Lensen, R&D Manager at AWL.

Two Ensenso X36 3D cameras provide the necessary image data. They are able to provide robust 2D and 3D information on products on a pallet measuring 1200 x 1200 mm and a maximum height of 2400 mm. The integrated image processing system processes this further and enables the depalletiser to identify each individual package and determine the corresponding gripping position – for robust robot-assisted picking.

3D cameras for future-oriented robotics

Each Ensenso X36 3D camera system consists of a projector unit and two GigE cameras with either 1.6 MP or 5 MP CMOS sensors. AWL has opted for the 5 MP variant for its solution. Mounting and adjustment brackets, three lenses as well as sync and patch cables for connecting the cameras to the projector unit are also included in the scope of delivery. The integrated FlexView2 technology ensures an even better spatial resolution as well as a very high robustness of the system with dark or reflective surfaces.

The 3D systems are delivered assembled and pre-calibrated. However, focussing and calibration is also easy to set up using the setup wizard integrated in the software. The latter they have in common with the RODE depalletiser – it is also easy to integrate into its working environment and aims to give its users a competitive edge in the world of logistics automation.

“The intralogistics market is a growth market. The number of robot solutions required will increase rapidly in the coming years. The type of products that need to be recognised will change constantly. This will be a challenge for all components and the demands on the camera,” explains Sander Lensen.

However, image processing is also developing rapidly. Smart solutions that combine camera technology with artificial intelligence are on the rise. They hold great potential for tackling both increasingly demanding tasks and the worsening shortage of skilled workers. Carton by carton, parcel by parcel, pallet by pallet.

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“In October, we will be presenting a large number of new and further developments at booth 8C60 at the Stuttgart trade fair,” announces Philipp Ohl, Head of Product Management at IDS. “One of the particularly interesting products will be a 2D camera with an event-based sensor, which will benefit motion analyses or high-speed counting.”

The 2D camera product area is proving to be extremely dynamic in the VISION year. IDS is expanding the range for customers and applications with many new sensors. Particularly noteworthy are the Sony Starvis 2 sensors IMX662, IMX664, IMX675 and IMX676, which enable impressive low-light performance and are available in the entry-level cameras of the uEye XCP and XLS series.

Applications in the field of robotics are highly dependent on 3D information. With Ensenso B, IDS will soon be launching an ultra-compact 3D camera that can work at close range and with a large field of view. The stereo vision camera, measuring just 120 x 56 x 104 millimetres, provides 3D information from a distance of approx. 20 centimetres. It will be on show at VISION in one of the many demo systems. And there is more: IDS will be presenting the first time-of-flight 3D camera to be developed entirely in-house as a prototype.

IDS will also be demonstrating further developments in image processing with artificial intelligence. This includes the all-in-one ecosystem IDS NXT, which was recently expanded to include the IDS NXT malibu camera model. The edge device combines on-camera AI, streaming in 4K and video compression. Visitors to the stand can also find out how characters can be reliably recognised even under difficult conditions thanks to DENKnet and the associated high-performance OCR model.

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The manufacturing sector is currently facing a number of challenges. Technological change, pressing environmental issues and globalisation require a number of adjustments, such as investing in new technologies, conserving resources and optimising and securing supply chains.

Globally operating companies have to face a changing environment and at the same time manage problems in supply chains. Shifting production back to the domestic market is increasingly an option. This requires not only resilience, but also compliance with strict environmental regulations and cost-efficient strategies to make domestic manufacturing competitive.

Moreover, those who want to ensure the competitiveness of domestic production must overcome personnel bottlenecks.

Automation through robotics has long since become the driving force here, and artificial intelligence (AI) is increasingly taking on a key role. This technology is developing just as rapidly as the pressure for automation is increasing. In order to map production processes in one’s own company with AI, the simplest possible AI integration and the shortening of training phases are already decisive factors.

This is where British start-up Cambrian Robotics comes in with a fully AI-based solution for various robotics applications in manufacturing. It takes over fast bin picking or pick-and-place, the exact feeding of parts for machines as well as different work steps in material handling – for the benefit of more efficiency in assembly tasks or in warehouse logistics.

The easy-to-integrate system consists of a module for robot arms, a computing unit with pre-installed intelligent software and a camera module, each equipped in series with two uEye+ XCP cameras from IDS.

“The task of the cameras is to take a picture of the area with the objects to be handled. Based on the recordings, the software can analyse the scene and recognise where exactly the objects are located,” explains Miika Satori, founder and CEO of Cambrian Robotics.

Further processing of the images is carried out with the help of the heart of Cambrian Vision – a specially developed, self-learning software for predicting the position of the parts as well as their pick points. This takes care of the image matching on an AI basis, so that no classic 3D point cloud is needed. Based on simulated data, the AI learns independently and locates the removal points and parts extremely precisely.

The AI models for part recognition and communication with the robot are controlled by a powerful GPU (Graphics Processing Unit). And the software learns quickly: “With the Cambrian software package, pick points for new parts can be defined and the application configured within just two to five minutes,” emphasises start-up founder Satori.

The associated camera module is equipped with two space-saving uEye XCP industrial cameras. “The two IDS cameras provide images of the object scene from different viewing angles according to the stereo vision principle. The challenge is to determine the position of the part to be gripped as accurately as possible from these images. This is again the task of AI,” says Miika Satori.

The combination of image acquisition, AI models and special image processing makes it possible to determine recording points and positions particularly precisely. Standard CAD applications for 3D bin picking often use structured light or sensors to do this, projecting something onto the environment, creating a point cloud and then trying to find the part in it. Cambrian uses only two standard IDS industrial cameras instead of a 3D camera.

Accuracy is better than 1mm. “The system reliably detects a wide range of parts, including shiny, reflective or transparent components, where conventional machine vision systems often reach their limits. At the same time, it remains robust against external light conditions,” says Miika Satori, describing the special requirements for the cameras, which are an elementary part of the solution.

“It’s also super-fast, with an inference speed of less than 170 milliseconds, whereas it often takes more than 1000 milliseconds for comparable solutions.” The fast calculation time allows cycle times of two to three seconds in a bin-picking setting. “This ensures efficient, precise and accurate execution in a single pass,” Miika Satori underlines. This makes the One-Shot system currently one of the fastest AI image recognition systems on the market.

This is made possible not least by the SuperSpeed USB 5 Gbps cameras, which reliably deliver high-resolution data for detailed image evaluations in any environment, explicitly in applications with low ambient light or changing light conditions. Thanks to BSI (‘Back Side Illumination’) pixel technology, the integrated sensor (1/2.5″ 5.04 MPixel rolling shutter CMOS sensor onsemi AR0521) offers stable low-light performance as well as high sensitivity in the NIR (near infrared) range, so that the uEye XCPs deliver high-quality images in almost any lighting situation – with low pixel noise at the same time.

With its compact, lightweight full housing (29 x 29 x 17 millimetres, 61 grams) and screwable USB Micro-B connector, the USB3 XCP is particularly suitable for use in combination with robots and cobots in the field of automation.

Thanks to USB3 and Vision Standard compatibility (U3V / GenICam), the XCP cameras can be easily integrated into any image processing system and can basically be used with any suitable software. The simple integration via the standard interface is particularly advantageous for Miika Satori: “Depending on the customer’s requirements, we use other IDS cameras in our system. The standardised interface enables rapid deployment of a wide variety of uEye models.”

Compatible with popular lenses, a wide range of cameras from the IDS portfolio can be used as eyes for custom Cambrian Vision solutions, helping to maximise production performance.

The top speed, the particularly high light insensitivity and the wide component bandwidth that the system achieves thanks to the powerful IDS cameras and intelligent software make it particularly interesting for automation tasks in the production environment.

Another key to efficiency lies in the uncomplicated integration of Cambrian Vision. The intelligent 3D vision system is ready for immediate use without any real robot training – a remarkable acceleration compared to conventional methods. Companies can therefore quickly reap the benefits of automation: They conserve resources and save costs by operating more efficiently, competitively and sustainably, while improving the quality of their products and the safety of their employees.

“The use of AI in robotics is still in its infancy,” says Miika Satori. Due to the growing demand, the development in the field of image processing with AI will be further advanced, cameras with higher data rates and faster and larger sensors will come onto the market, as well as further price-optimised models with reliable basic functions.

“Industrial cameras are getting smaller and more affordable. This will enable even more applications. Our vision is to give robots capabilities on the same level as humans.”

By using AI-powered robots for mundane and repetitive tasks, human resources can be redirected to more creative, productive and valuable tasks.

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