Fill Level & Coverage Inspection
Ensuring Proper Material Application and Completeness
Our cameras ensure proper application and completeness of materials across bonding, sealing, and coating processes - vital for product function, seal integrity, and long-term quality.
Key Applications
Seam Sealant Inspection
For critical seam sealant applications, the OV20i tackles the challenge of detecting subtle defects like pinholes and dirt that are often too small for existing inspection systems. This system utilizes breakthrough vision transformer AI to build an accurate inspection model with as few as five images, effectively reducing false negatives where defects previously went unnoticed. The OV20i ensures the quality and consistency of sealant applied to car seams, which is crucial for preventing water leaks and maintaining vehicle durability.
Coverage & Fill Inspection Across Processes
Our AI adapts to a wide range of material application processes - verifying completeness, uniformity, and adherence to specification.
Seam Sealant
Verify bead continuity, width, and coverage on automotive seams that prevent water leaks and corrosion.
Adhesive Beads
Inspect adhesive bead application for proper width, height, and gap-free continuity in bonding processes.
Coating & Paint
Detect thin spots, runs, drips, and uncoated areas across painted or coated surfaces at production speed.
Fill Level
Verify fill volumes in containers, bottles, and reservoirs - flagging under-fills and over-fills in real time.
Why Manufacturers Choose Overview AI
Breakthrough AI that catches what existing inspection systems miss on sealant and coverage applications.
Vision Transformer AI
Breakthrough vision transformer models build accurate inspection with as few as 5 training images.
Pinhole-Level Detection
Detect pinholes, dirt, and subtle coverage gaps that are too small for existing inspection systems to catch.
Zero Missed Defects
Eliminates false negatives that let defects slip through, ensuring every seam meets durability standards.
From Install to Production in Hours
No months-long integrations. No dedicated vision specialists. Just fast, accurate inspection.
Install & Configure
Mount the camera, connect to your network via any browser - no software installs, no license keys. Full system operational in under 2 hours.
Train with Real Images
Capture as few as 5 production images, label defects in-browser, and train a production-grade model. Built-in augmentation generates 10x more training data automatically.
Deploy & Retrain
Push the model to the camera - no export steps, no IT tickets. Retrain on new edge cases from the production floor in under 1 hour, zero downtime.
Built for the Factory Floor
Enterprise-grade hardware and software designed for 24/7 industrial operation.
NVIDIA-powered on-device processing. No cloud dependency.
Store weeks of production data directly on each camera.
EtherNet/IP, Profinet, Modbus TCP - no middleware needed.
ISO 9001, ISO 27001 certified.
Node-RED on Every Camera
Visual programming for PLC triggers, reject mechanisms, data logging, and MES/ERP integration via REST APIs.
Custom Dashboards
Build operator, engineer, and management views with standard HTML/CSS/JS. Access from any browser on the network.
Haystack Discovery
Surface unknown defects and outliers automatically. Retrain to catch them - no vendor involvement required.
FAQ
Frequently asked questions
How does a vision system measure fill level?
For a clear container, backlighting is the usual answer. Light behind the container turns the liquid boundary into a crisp silhouette edge, which is the most repeatable feature any measurement can be built on. The system locates that edge, converts the pixel position into millimetres using a calibration, and compares it against the high and low limits. Opaque containers cannot be measured that way and need either a different wavelength, a view through a fill port, or a weight check alongside the vision result.
Can it check adhesive or coating coverage, not just height?
Yes, and it is a different kind of measurement. Fill height is a single dimension against a tolerance. Coverage is an area judgment: what fraction of the intended region actually has material on it, and is the bead continuous. That means the acceptance criterion has to be agreed before the system is built, because "enough glue" is not a number until someone makes it one. Coverage also usually needs lighting chosen to separate the material from what it sits on, which is often a colour or gloss difference rather than a shape difference.
Does the line have to stop for the inspection?
No. Fill and coverage checks run on moving product, which is the normal case on a filling line. What matters is that the exposure is short enough that motion does not smear the boundary you are measuring, which in practice means bright, well-placed light rather than a longer shutter. The trigger also has to be consistent, so the container is in the same part of the frame every time.
Ready to Automate Material Coverage Inspection?
See how Overview AI vision deployments drive real results in days, not months.