SENSURE Software Suite
powered by SYNAPSE
SENSURE Software Suite (powered by SYNAPSE, expandable with DATAVIEW and DATAMIND optional modules) is an AI-powered comprehensive solution for measurement, defect detection, and classification, supporting external data integration from machinery and IIoT devices, PLC/Robot communication, SQL storage, web-based visualization, and advanced data analytics tools for process improvement.
DATAVIEW
DATAMIND
SENSURE Software Suite (powered by SYNAPSE, expandable with DATAVIEW and DATAMIND optional modules) is an AI-powered comprehensive solution for measurement, defect detection, and classification, supporting external data integration from machinery and IIoT devices, PLC/Robot communication, SQL storage, web-based visualization, and advanced data analytics tools for process improvement.
Overview
The AI-based SYNAPSE license provides a powerful and comprehensive suite of tools for measurement, image processing, and defect detection, enabling 100% inline inspection of the entire production output. It is engineered to exceed the industry's highest standards.
Three complementary inspection modes address different production challenges:
  • Self-Learning approach for automatic quality control and defect detection.
  • Deep Learning approach for the identification and quantification of toppings and ingredients.
  • Template Matching approach for low-variability products, where precise comparison with a reference model is required.
Sensure
The SYNAPSE license includes the following functions
Main features
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  • Innovative web-based Graphical User Interface (GUI) featuring a user-friendly and intuitive layout for immediate interaction between line operators and the different SENSURE vision inspection systems installed in the line.
  • Real-time gauges displaying live values of specific product features and/or process parameters, with customizable settings for which features to display and their intervals (good and warning states) to enhance data visibility.
  • Advanced image processing operations, including image acquisition from different sensors and devices (smart hardware integration), pre-processing, and segmentation, ensuring high precision and efficiency for industrial applications.
  • An extensive set of features for quality measurement parameters (shape, size, color, thickness, etc. depending on the installed vision hardware), developed through nearly two decades of experience in the industry, with the possibility to add customized ones (subject to feasibility analysis). Product recipes are defined through these features via an intuitive recipe setting interface, enabling easy threshold configuration while providing visibility of the historical trends of the measured features.
  • Storage of the average measurement values for each feature (at time intervals configurable by the customer) in a database (SQL, NoSQL, or cloud platforms such as AWS, Azure, or Google Cloud) to ensure data reliability and enable advanced data analysis. Data transfer is possible using different protocols in an optimized way (OPC UA, Ethernet IP, MODBUS, TCP, MQTT, etc.). Possibility to delivery, subject to case-by-case evaluation based on the speed of the line, the complete product information via an MQTT channel (on a dedicated MQTT server).
  • Detection and communication of product quality features, center of mass, orientation, etc. to I/O Boards, PLC, Controllers, and Robots for rejection, and pick-and-place activities.
  • Communication with PLCs, SCADA systems, external databases, IIoT devices, and other relevant environmental and operational factors along the production line, for the integration of process data with product measurements.
  • Tools for fast system calibration and verification, ensuring consistently reliable, repeatable, and accurate measurements.
  • Multilanguage system with user and access management with the ability to define individual permissions for different groups.
  • Accessibility from any device connected to the network, including desktops, tablets, and smartphones.
  • Fully customizable interface available upon request (additional development subject to quotation).
  • Access to production data statistical charts (by features, shifts, lanes, etc.) and defect detection analysis (including explanations for rejection causes, images of all detected defects) based on all information from the previous 24 hours. For complete analysis over extended time periods, the integration of the DATAVIEW license is required.
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AI and Self-Learning
  • Thanks to the LEARN button on the intuitive GUI, the system automatically proposes a quality recipe and tolerance thresholds (without requiring samples for a manual classification of non-compliances), eliminating the complicated part of setup typical of traditional systems. The system also allows the operator to make subsequent modification. Thanks to the ability to work in self-learning, SYNAPSE presents a quick and easy installation and setup phase.
  • With the LEARN functionality implemented, the line operator decides when to adapt the system in order to maintain the highest quality standards with the appropriate analysis thresholds, allowing it to continuously respond to variations on the production line (e.g. oven drifts, ambient light changes, different incoming raw materials, suboptimal product recipes, dirty conveyor belts, etc.).