AOI - Automatic Optical Inspection Systems

Goepel Gmbh Automatic Optical and X ray Inspection machines

Industrial Location in Jena – a Pool of Knowledge andExperience For many years Jena has been a place of technical and scientificprogress. Masterminds such as Carl Zeiss, Ernst Abbe andOtto Schott founded the optical instrumentation manufacturingindustry there and led it to world-wide acceptance of innovationand quality. Carl Zeiss Jena and Schott became internationally acceptedcorporations, from which numerous high-tech companiesoutsourced in the early 1990s. They realised innovative ideasand successfully established themselves within their marketsegments. One of these companies is GOEPEL electronic.
AOI Systems


  1. OptiCon TurboLine


  2. OptiCon AdvancedLine


  3. OptiCon
    BasicLine




  4. OptiCon SmartLine



  5. OptiCon THT-Line



  6. OptiCon SPI-Line 3D



  7. Chameleon
X-Ray inspection System


  1. OptiCon X-Line 3D
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OptiCon TurboLine - AOI high end inspection



AOI System that delivers high-end inspection during large volume production and ensures superior quality for high value PCBs
According to a repeatedly conducted customer survey, 98% of our customers gladly recommend the AOI products of GOEPEL electronic.
Specifics of the AOI high end inspection:
  1. Camera module for microscopic resolution in the AOI inspection
  2. Excellent angled-view quality with complete coverage of the orthogonal camera’s field of view
  3. Angled view inspection of components in any angular position
  4. Runtime minimisation by segmented conveyor module and double sided inspections
  5. Extremely wide spectrum of configuration options for ideal adjustment to the required application in the manufacturing process for the AOI inspection
  6. Upgradeability of all modules and functions due to high system modularity for the AOI inspection
  » Camera
  1. Orthogonal View and angled-view inspection

    Configuration Variants:

    » 4 angled-view cameras, offset 90°, rotary drive rotation range    360°
    » 4 angled-view cameras, offset 90°, without rotary drive
    » 2 angled-view cameras, offset 180°, rotary drive rotation range    360°
    » 1 angled-view cameras, rotary drive rotation range 270°

    Top and bottom side Orthogonal Inspection possible!

  » Illumination

Flexible Multispectral Illumination

  1. Multi-spectral illumination, selectable from IR to UV
  2. Selectable intensity and illumination direction

Contrast Enhancement by Illumination Variety

The illumination module of an AOI system is highly responsible for a safe separation of faulty solder joints and components from process variations. A flexible illumination concept provides the basis for ideal contrast ratio with respect to image analysis.

Freely selectable from Infrared to Ultraviolet

The OptiCon systems feature illumination modules with controllable wave length, intensity and direction. They also guarantee safe detection of low-contrast components, polarity marks, material differences and contaminations.
These features provide the basis for safe high detection of production faults as well as false call rate minimisation. All illumination variants are predefined in library entries for automatic program generation and can be adjusted for a specific PCB if required.

  » Software

OptiCon PILOT – a well-balanced Software Concept

The OptiCon PILOT software provides powerful functions for component recognition, solder joint and short inspection, OCR, colour verification as well as solder paste inspection.

In addition to the intelligent component recognition based on automated characteristic extraction from real images, the solder joint quality is determined by a complex grey value analysis using a range of illumination types.

For automatic test program generation a flexible import module for numerous placement data, gerber data and CAD formats is available.

Generated test programs and library entries can be transferred to various systems and used independently from component position or PCB background with constantly high inspection quality.

  » Process Integration

OptiCon PILOT – reliable Integration within a Company-specific Production Process

The powerful modules of the OptiCon PILOT software enable an efficient integration of the AOI systems into company-specific production and quality assurance processes.

The repair station software offers convenient handling in the in-line process for fault verification as well as for offline repair by means of a coloured display of the detected faults and overview image. Additionally, it allows a program optimisation during the current production process.

Extensive statistic evaluations with numerous filter settings enable the fast detection of main faults as well as an objective evaluation of production quality and throughput.

In addition to test program generation, the offline programming software allows the program optimisation inclusive adaptation of illumination settings without affecting the test throughput at the AOI system.

The SPC module (statistic process control) enables an effective optimisation of the production process of mounted PCBs. Warning limits and action limits can be defined for selected component parameters.

Trend analyses allow anticipatory acting before a fault occurs.

  » Reference-Database

Reference-Database

The integrated reference database guarantees safe and documented fault detection at optimised false call rate. It enables the storage of previously detected faults and their verification after test program modifications. In case of inconsistent results after a program check, all corresponding parameters will be displayed. Likewise, the reference database serves as storage for PASS examples to ensure the stability of optimised test programs.

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OptiCon AdvancedLine X30 / X45 / X60



In-line AOI system with flexible integration opportunities into manufacturing lines as well as stand-alone solutions with automatic loading and sorting options.
  » Camera
  1. Camera and Lens

    » Pixel adapted camera module for all system variants
    » Telecentric lens for parallax-free image capturing
    » Multi-directional image capturing by means of 360° angled-view module rotation
    » Adapted focal plane at consistent image quality for angled-view inspection

Add-on Camera and Laser Height Measurement System

For an extension in fault coverage an additional camera and a high-resolution Laser height measurement system can be integrated into the OptiCon systems for test tasks respectively.

  » Illumination

Flexible Multispectral Illumination

  1. Multi-spectral illumination, selectable from IR to UV
  2. Selectable intensity and illumination direction

Contrast Enhancement by Illumination Variety

The illumination module of an AOI system is highly responsible for a safe separation of faulty solder joints and components from process variations. A flexible illumination concept provides the basis for ideal contrast ratio with respect to image analysis.

Freely selectable from Infrared to Ultraviolet

The OptiCon systems feature illumination modules with controllable wave length, intensity and direction. They also guarantee safe detection of low-contrast components, polarity marks, material differences and contaminations.
These features provide the basis for safe high detection of production faults as well as false call rate minimisation. All illumination variants are predefined in library entries for automatic program generation and can be adjusted for a specific PCB if required.

  » Software

OptiCon PILOT – a well-balanced Software Concept

The OptiCon PILOT software provides powerful functions for component recognition, solder joint and short inspection, OCR, colour verification as well as solder paste inspection.

In addition to the intelligent component recognition based on automated characteristic extraction from real images, the solder joint quality is determined by a complex grey value analysis using a range of illumination types.

For automatic test program generation a flexible import module for numerous placement data, gerber data and CAD formats is available.

Generated test programs and library entries can be transferred to various systems and used independently from component position or PCB background with constantly high inspection quality.

  » Process Integration

OptiCon PILOT – reliable Integration within a Company-specific Production Process

The powerful modules of the OptiCon PILOT software enable an efficient integration of the AOI systems into company-specific production and quality assurance processes.

The repair station software offers convenient handling in the in-line process for fault verification as well as for offline repair by means of a coloured display of the detected faults and overview image. Additionally, it allows a program optimisation during the current production process.

Extensive statistic evaluations with numerous filter settings enable the fast detection of main faults as well as an objective evaluation of production quality and throughput.

In addition to test program generation, the offline programming software allows the program optimisation inclusive adaptation of illumination settings without affecting the test throughput at the AOI system.

The SPC module (statistic process control) enables an effective optimisation of the production process of mounted PCBs. Warning limits and action limits can be defined for selected component parameters.

Trend analyses allow anticipatory acting before a fault occurs.

  » Reference-Database

Reference-Database

The integrated reference database guarantees safe and documented fault detection at optimised false call rate. It enables the storage of previously detected faults and their verification after test program modifications. In case of inconsistent results after a program check, all corresponding parameters will be displayed. Likewise, the reference database serves as storage for PASS examples to ensure the stability of optimised test programs.

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OptiCon BasicLine X30 / X45 / X60



Stand-alone AOI system for manual loading and simple adaptation for PCBs, single components and complex assemblies.
According to a repeatedly conducted customer survey, 98% of our customers gladly recommend the AOI products of GOEPEL electronic.
  » Camera
  1. Orthogonal View and angled-view inspection

    Configuration Variants:

    » Pixel adapted camera module for all system variants
    » Telecentric lens for parallax-free image capturing
    » Multi-directional image capturing by means of 360° angled-view module rotation
    » Adapted focal plane at consistent image quality for angled-view inspection

Add-on Camera and Laser Height Measurement System

For an extension in fault coverage an additional camera and a high-resolution Laser height measurement system can be integrated into the OptiCon systems for test tasks respectively.

  » Illumination

Flexible Multispectral Illumination

  1. Multi-spectral illumination, selectable from IR to UV
  2. Selectable intensity and illumination direction

Contrast Enhancement by Illumination Variety

The illumination module of an AOI system is highly responsible for a safe separation of faulty solder joints and components from process variations. A flexible illumination concept provides the basis for ideal contrast ratio with respect to image analysis.

Freely selectable from Infrared to Ultraviolet

The OptiCon systems feature illumination modules with controllable wave length, intensity and direction. They also guarantee safe detection of low-contrast components, polarity marks, material differences and contaminations.
These features provide the basis for safe high detection of production faults as well as false call rate minimisation. All illumination variants are predefined in library entries for automatic program generation and can be adjusted for a specific PCB if required.

  » Software

OptiCon PILOT – a well-balanced Software Concept

The OptiCon PILOT software provides powerful functions for component recognition, solder joint and short inspection, OCR, colour verification as well as solder paste inspection.

In addition to the intelligent component recognition based on automated characteristic extraction from real images, the solder joint quality is determined by a complex grey value analysis using a range of illumination types.

For automatic test program generation a flexible import module for numerous placement data, gerber data and CAD formats is available.

Generated test programs and library entries can be transferred to various systems and used independently from component position or PCB background with constantly high inspection quality.

  » Process Integration

OptiCon PILOT – reliable Integration within a Company-specific Production Process

The powerful modules of the OptiCon PILOT software enable an efficient integration of the AOI systems into company-specific production and quality assurance processes.

The repair station software offers convenient handling in the in-line process for fault verification as well as for offline repair by means of a coloured display of the detected faults and overview image. Additionally, it allows a program optimisation during the current production process.

Extensive statistic evaluations with numerous filter settings enable the fast detection of main faults as well as an objective evaluation of production quality and throughput.

In addition to test program generation, the offline programming software allows the program optimisation inclusive adaptation of illumination settings without affecting the test throughput at the AOI system.

The SPC module (statistic process control) enables an effective optimisation of the production process of mounted PCBs. Warning limits and action limits can be defined for selected component parameters.

Trend analyses allow anticipatory acting before a fault occurs.

  » Reference-Database

Reference-Database

The integrated reference database guarantees safe and documented fault detection at optimised false call rate. It enables the storage of previously detected faults and their verification after test program modifications. In case of inconsistent results after a program check, all corresponding parameters will be displayed. Likewise, the reference database serves as storage for PASS examples to ensure the stability of optimised test programs.

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OptiCon SmartLine X25



Desktop AOI system for efficient inspection of small volumes and single boards. Its compact design enables a space-saving utilisation at various positions in the production process.
  » Camera
  1. Orthogonal View and angled-view inspection

    Configuration Variants:

    » Pixel adapted camera module for all system variants
    » Telecentric lens for parallax-free image capturing
    » Adapted focal plane at consistent image quality for angled-view inspection

Add-on Camera and Laser Height Measurement System

For an extension in fault coverage an additional camera and a high-resolution Laser height measurement system can be integrated into the OptiCon systems for test tasks respectively.

  » Illumination

Flexible Multispectral Illumination

  1. Multi-spectral illumination, selectable from IR to UV
  2. Selectable intensity and illumination direction

Contrast Enhancement by Illumination Variety

The illumination module of an AOI system is highly responsible for a safe separation of faulty solder joints and components from process variations. A flexible illumination concept provides the basis for ideal contrast ratio with respect to image analysis.

Freely selectable from Infrared to Ultraviolet

The OptiCon systems feature illumination modules with controllable wave length, intensity and direction. They also guarantee safe detection of low-contrast components, polarity marks, material differences and contaminations.
These features provide the basis for safe high detection of production faults as well as false call rate minimisation. All illumination variants are predefined in library entries for automatic program generation and can be adjusted for a specific PCB if required.

  » Software

OptiCon PILOT – a well-balanced Software Concept

The OptiCon PILOT software provides powerful functions for component recognition, solder joint and short inspection, OCR, colour verification as well as solder paste inspection.

In addition to the intelligent component recognition based on automated characteristic extraction from real images, the solder joint quality is determined by a complex grey value analysis using a range of illumination types.

For automatic test program generation a flexible import module for numerous placement data, gerber data and CAD formats is available.

Generated test programs and library entries can be transferred to various systems and used independently from component position or PCB background with constantly high inspection quality.

  » Process Integration

OptiCon PILOT – reliable Integration within a Company-specific Production Process

The powerful modules of the OptiCon PILOT software enable an efficient integration of the AOI systems into company-specific production and quality assurance processes.

The repair station software offers convenient handling in the in-line process for fault verification as well as for offline repair by means of a coloured display of the detected faults and overview image. Additionally, it allows a program optimisation during the current production process.

Extensive statistic evaluations with numerous filter settings enable the fast detection of main faults as well as an objective evaluation of production quality and throughput.

In addition to test program generation, the offline programming software allows the program optimisation inclusive adaptation of illumination settings without affecting the test throughput at the AOI system.

The SPC module (statistic process control) enables an effective optimisation of the production process of mounted PCBs. Warning limits and action limits can be defined for selected component parameters.

Trend analyses allow anticipatory acting before a fault occurs.

  » Reference-Database

Reference-Database

The integrated reference database guarantees safe and documented fault detection at optimised false call rate. It enables the storage of previously detected faults and their verification after test program modifications. In case of inconsistent results after a program check, all corresponding parameters will be displayed. Likewise, the reference database serves as storage for PASS examples to ensure the stability of optimised test programs.

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Optical inspection of THT assemblies with OptiCon THT-Line



AOI System for efficient quality assurance of THT Assemblies in the production process. It can be utilised either per manual feeding or as an in-line system utilising a roller conveyor transport system.
OptiCon THT-Line enables the automated inspection of THT assemblies with up to 80 mm component height.



OptiCon THT-Line wins "Industriepreis 2012" in category "optical technologies".
  » Camera

The camera concept

The camera enables high-contrast gray value capturing as well as high resolution colour images based on the Extended Colour Technology™.
The extended depth of field enables the inspection of THT assemblies with up to 80 mm component height.

  » Illumination

Flexible Multispectral Illumination

  1. Multi-spectral illumination, selectable from IR to UV
  2. Selectable intensity and illumination direction

Contrast Enhancement by Illumination Variety

The illumination module of an AOI system is highly responsible for a safe separation of faulty solder joints and components from process variations. A flexible illumination concept provides the basis for ideal contrast ratio with respect to image analysis.

Freely selectable from Infrared to Ultraviolet

The OptiCon systems feature illumination modules with controllable wave length, intensity and direction. They also guarantee safe detection of low-contrast components, polarity marks, material differences and contaminations.
These features provide the basis for safe high detection of production faults as well as false call rate minimisation. All illumination variants are predefined in library entries for automatic program generation and can be adjusted for a specific PCB if required.

  » Software

OptiCon PILOT – a well-balanced Software Concept

The OptiCon PILOT software provides powerful functions for component recognition, solder joint and short inspection, OCR, colour verification as well as solder paste inspection.

In addition to the intelligent component recognition based on automated characteristic extraction from real images, the solder joint quality is determined by a complex grey value analysis using a range of illumination types.

For automatic test program generation a flexible import module for numerous placement data, gerber data and CAD formats is available.

Generated test programs and library entries can be transferred to various systems and used independently from component position or PCB background with constantly high inspection quality.

  » Process Integration

OptiCon PILOT – reliable Integration within a Company-specific Production Process

The powerful modules of the OptiCon PILOT software enable an efficient integration of the AOI systems into company-specific production and quality assurance processes.

The repair station software offers convenient handling in the in-line process for fault verification as well as for offline repair by means of a coloured display of the detected faults and overview image. Additionally, it allows a program optimisation during the current production process.

Extensive statistic evaluations with numerous filter settings enable the fast detection of main faults as well as an objective evaluation of production quality and throughput.

In addition to test program generation, the offline programming software allows the program optimisation inclusive adaptation of illumination settings without affecting the test throughput at the AOI system.

The SPC module (statistic process control) enables an effective optimisation of the production process of mounted PCBs. Warning limits and action limits can be defined for selected component parameters.

Trend analyses allow anticipatory acting before a fault occurs.

  » Reference-Database

Reference-Database

The integrated reference database guarantees safe and documented fault detection at optimised false call rate. It enables the storage of previously detected faults and their verification after test program modifications. In case of inconsistent results after a program check, all corresponding parameters will be displayed. Likewise, the reference database serves as storage for PASS examples to ensure the stability of optimised test programs.

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3D Solder Paste Inspection - as fast as never before

OptiCon SPI-Line 3D

The OptiCon SPI-Line 3D enables precise three-dimensional solder paste printing measurement in terms of height, volume, offset and smearing.

The core element is a specifically developed 3D camera head functionally based on the fringe projection principle, operating without moving parts. There are three different system configurations determined by lateral resolutions of 10 μm, 15 μm and 20 μm.

In high-speed mode the system achieves an inspection speed of up to 90 cm²/s with extraordinary precision.

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OptiCon X-Line 3D



3D in-line X-ray inspection system for maximum fault coverage using digital tomosynthesis with outstanding inspection speed.

Benefits of the 3D X-Ray Inspection:

  1. Safe inspection of double-sided assembled PCBs
  2. Reconstruction of any layers
  3. patial allocation of deteted faults
  4. Fast and user friendly test programm generation by using a single unified library
  » Image Capture
» Complete 3D capturing can achieve test speeds of up to 40cm²/s    by revolutionary GigaPixel™ technology
» Reconstruction processes possible due to tomosynthesis
» Simultaneous 3D x-ray inspection of top and bottom side of a    double sided PCB
» Optimal adaptation to future components and manufacturing    requirements via Software XI-PILOT
» Algorithm library suitable for all common components
» Minimal times for test program generation

  » Process integration
The offline programming software allows following a one-time endurance run of a PCB in the test system a complete test program generation and library adjustment at a separate PC.
» Repair station software enables a visualisation of detected faults in various forms of presentation » Powerful analysis software allows for the inspection of single layers » objective rating of production quality and throughput with the help of comprehensive statistical evaluation package with numerous filter settings » Warning and action limits as well as trend analyses are definable in the SPC Module

  » Database
» Layered reconstruction of components and solder joints » Test program generation and actual inspection process are executed with geometrically calibrated, distortion free imaging of the real test objects » Fast test program generation based on CAD data using a component library » Predefined test algorithms and classifiers

  » Fault Detection
» Full-sized 3D x-ray inspection (AXI) allows layered analysis of all solder joints of a PCB within the production process » Safe detection of critical faults and spatial allocation of the detected defects

  » Fault Analysis

Reference-Database

» Powerful analysis software provides the safe evaluation of detected faults » Detailed examination of the inspection results in various Z-levels » Clear representation of soldered joints and components via visualisation of selected areas

  » News

Who cares about warped surfaces?

Spacial Correction of PCB Deflection with OptiCon X-Line 3D

3D x-ray inspection systems are able to generate digital crosssection images of an assembly. In this way, double-sided equipped PCBs can be simultaneously inspected from top and bottom sides by layered solder joint separation.

A true to height reconstruction of PCB layers in which solder joints are situated is a prerequisite for solder joint analyses.

What happens if a PCB is warped or waved?

A 3D x-ray inspection system must detect and compensate for such a situation. For example, if the warp in an assembly is not compensated, evaluation algorithms check in the wrong solder layers of a component, which may lead to false calls or even escape.

GOEPEL electronic GmbH utilises a purpose developed method, which detects and compensates PCB slag during the inspection process. The result is a true to height solder layer reconstruction for a high-quality evaluation of solder joints. Based on PCB condition it is possible to select whether the entire assembly or each partial circuit of a value should be compensated.

For PCB warpage determination, a laser triangulation sensor can be applied. It is also possible to compensate for PCB slag directly in the recorded images per software algorithmic.

X-ray System monitors itself!

Automatic Stability Monitoring of X-ray Image Sequence in OptiCon X-Line 3D System

An X-ray inspection system image sequence generally consists of a source for x-ray emission and a detector to convert radiation weakened by the UUT into visible light.

Natural ageing processes of these components change grey values in the x-ray images, which may lead to faults in algorithmic evaluation of solder joints.

The AXI system OptiCon X-Line 3D automatically detects changes in the x-ray image chain and re-calibrates the images chain at lower deviations of the acceptable tolerances. Thus, it is possible to guarantee constant image quality and measurement values in the system during the inspection process. It ensures that image geometry characteristics as well as intensity (grey values) are situated in an adjustable tolerance range.