Retrofitting an industrial vision system rarely fails because of the camera itself in practice, but because of insufficient integration into the existing system. A successful retrofit either fixes existing instabilities (false alarms, downtime) through modern software algorithms and ambient-light protection, or extends the system with code readers (DataMatrix, OCR) to capture part data for the digital twin.
Scenario A: The existing camera system is causing problems – root cause analysis
Many older or poorly designed image-processing systems suffer from a lack of process reliability. The result is high false-reject rates (good parts identified as defective) and costly line stoppages. Before replacing components, precise root-cause analysis comes first:
- Optical instability: Does hall lighting change over the course of the day (sunlight)? Do LED lights drift due to ageing?
- Mechanical play: Have machine vibrations minimally changed the lens focus or camera position?
- Software rigidity: Does the system still work with rigid thresholds that fail under minimal batch variation in material?
Our inspection systems replace error-prone legacy systems with AI-supported or algorithmically robust image processing. Through the use of modern LED flash controllers and software-side brightness normalisation, we make your inspection independent of external disturbance variables – we explain the technical background in our article on ambient light in vision systems.
Scenario B: Retrofitting for the digital twin (traceability)
More and more end customers require proof that every individual part has passed through the manufacturing process without defects. Here, the vision system serves as the data source for the digital twin.
- Data capture at the line: Cameras capture DataMatrix codes (DMC), barcodes or laser-marked serial numbers (OCR) applied directly after injection moulding or assembly.
- Linking inspection data: The THOPinspect system inspects the part for quality (e.g. flash or scratches) and links this measurement result directly with the serial number that was read.
- Interface to IT (MES/ERP): Using modern communication protocols such as OPC UA or MQTT, this data is transferred to your higher-level database in real time. The part receives its digital twin.
The 3 biggest challenges in retrofitting – and how to solve them
One of the most common technical hurdles concerns the connection to the existing PLC, particularly with older control generations:
| Retrofit challenge | The risk in practice | The THOP solution |
|---|---|---|
| Limited installation space | Existing machines rarely have room for large inspection cells. | The THOPinspect Unit is built extremely compact and can be flexibly integrated even into the tightest machine spaces. |
| Old PLC controls | The existing PLC (e.g. an older Siemens S7) doesn't speak modern protocols. | We master the bridge between old and new – from classic digital I/Os (24V signals) through to Profinet and OPC UA. |
| Production downtime | The conversion must not block ongoing production for days. | Through intensive preparation and simulation in the THOP lab, commissioning on your line is usually completed within a few hours. |
A retrofit doesn't have to be risky. Take advantage of our open, interface-agnostic system architecture. We analyse your existing system on site or from construction drawings and show you exactly how we can maximise the stability of your line.
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