6.5 Quality Control with AI (AIQS)

Overview

The AIQS (Quality Control with AI) module performs automated quality inspection using a camera and color sensor. It checks workpiece color and quality, then routes workpieces based on the result.

Module Type: AIQS
Serial Number: Cleaned variant of the SPS serial number

Supported Commands

Command	Purpose	Result Values	Duration
`PICK`	Pick workpiece from AGV	N/A	~3 seconds
`CHECK_QUALITY`	Inspect workpiece quality and color	`PASSED`, `FAILED`	~3 seconds (fixed)
`DROP`	Return workpiece to AGV	N/A	~3 seconds

Supported Instant Actions

Action	Purpose	Metadata	Description
`factsheetRequest`	Request module info	None	Triggers publication of factsheet message
`reset`	Reset module	None	Return module to initial state
`startCalibration`	Enter calibration mode	None	Switch operating mode to TEACHIN
`stopCalibration`	Exit calibration mode	None	Switch operating mode to AUTOMATIC
`setCalibrationValues`	Update calibration	Calibration data	Update internal position values

MQTT Topics

Standard module topics:

Subscribe: module/v1/ff/<serial>/order, module/v1/ff/<serial>/instantAction
Publish: module/v1/ff/<serial>/state, module/v1/ff/<serial>/connection, module/v1/ff/<serial>/factsheet

Command Example: CHECK_QUALITY

Command:

{
  "timestamp": "2024-12-08T12:00:00.000Z",
  "serialNumber": "AIQS001",
  "orderId": "order-check-456",
  "orderUpdateId": 1,
  "action": {
    "id": "check-action-789",
    "command": "CHECK_QUALITY"
  }
}

State Response (Running):

{
  "headerId": 51,
  "timestamp": "2024-12-08T12:00:01.000Z",
  "serialNumber": "AIQS001",
  "type": "AIQS",
  "orderId": "order-check-456",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "check-action-789",
    "timestamp": "2024-12-08T12:00:01.000Z",
    "state": "RUNNING",
    "command": "CHECK_QUALITY"
  },
  "errors": [],
  "loads": []
}

Result: PASSED

Workpiece passed inspection and is returned to AGV:

{
  "headerId": 52,
  "timestamp": "2024-12-08T12:00:04.000Z",
  "serialNumber": "AIQS001",
  "type": "AIQS",
  "orderId": "order-check-456",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "check-action-789",
    "timestamp": "2024-12-08T12:00:04.000Z",
    "state": "FINISHED",
    "command": "CHECK_QUALITY",
    "result": "PASSED"
  },
  "errors": [],
  "loads": []
}

Result: FAILED

Workpiece failed inspection and is routed to NiO (Not in Order) chute:

{
  "headerId": 52,
  "timestamp": "2024-12-08T12:00:04.000Z",
  "serialNumber": "AIQS001",
  "type": "AIQS",
  "orderId": "order-check-456",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "check-action-789",
    "timestamp": "2024-12-08T12:00:04.000Z",
    "state": "FINISHED",
    "command": "CHECK_QUALITY",
    "result": "FAILED"
  },
  "errors": [],
  "loads": [
    {
      "loadType": "WHITE",
      "loadPosition": "MODULE"
    }
  ]
}

When result is FAILED, the workpiece remains on the module's reject conveyor (NiO). The process ends here for this workpiece.

Quality Check Process

Pickup: Module picks workpiece from AGV (via PICK command)
Camera Inspection: Checks for physical defects
Color Detection: Verifies correct color
Routing:
- PASSED: Returns to AGV via main conveyor
- FAILED: Routes to NiO chute (reject area)

Hardware Details

PLC I/O

Inputs: Light barriers, suction sensors, camera sensor, color sensor, encoder
Outputs: Conveyor (bidirectional, PWM), suction actuator, compressor, camera lighting

Errors

CHECK_QUALITY_ERROR - Inspection failed (sensor fault)
PICK_ERROR - Failed to retrieve rejected workpiece

Special Considerations

Result Handling:

PASSED: Workpiece is ready to be dropped back to AGV (send DROP command).
FAILED: Workpiece is routed to NiO chute. The AGV is not used again for this order.

Complete Quality Check Flow

sequenceDiagram
    participant AGV
    participant CCU
    participant AIQS

    Note over AGV: 1. AGV docks at AIQS001
    
    CCU->>AIQS: 2. PICK command
    AIQS->>CCU: 3. State: FINISHED
    
    CCU->>AIQS: 4. CHECK_QUALITY command
    AIQS->>CCU: 5. State: RUNNING
    
    Note over AIQS: 6. Perform Inspection<br/>Camera, Color, Routing
    
    alt Result: PASSED
        AIQS->>CCU: 7a. State: FINISHED<br/>result: PASSED
        CCU->>AIQS: 8a. DROP command
        AIQS->>CCU: 9a. State: FINISHED
        Note over AIQS: Workpiece returned to AGV
        CCU->>AGV: clearLoadHandler
    else Result: FAILED
        AIQS->>CCU: 7b. State: FINISHED<br/>result: FAILED, loads: [workpiece]
        Note over AIQS: Workpiece on NiO reject area
        Note over CCU: Mark order as ERROR/CANCELLED
    end

Internal Communication (Node-RED to TXT)

The AIQS module uses a secondary TXT controller internally for camera operations. This controller communicates with the main Node-RED instance via a dedicated MQTT interface.

Topic Structure

The internal communication uses a nested topic structure: module/v1/ff/{DEVICEID}/{internal-TXT-DEVICEID}/...

Internal Order Message

There is only one supported internal order: CHECK_QUALITY.

Topic: module/v1/ff/{DEVICEID}/{internal-TXT-DEVICEID}/order

{
  "serialNumber": "{internal-TXT-DEVICEID}",
  "orderId": "SOME_ID",
  "orderUpdateId": 2,
  "timestamp": "2023-02-02T13:58:06Z",
  "action": {
    "timestamp": "2023-02-02T13:58:06Z",
    "command": "CHECK_QUALITY",
    "id": "ID#2",
    "metadata": {
      "type": "COLOR",
      "workpieceId": "some_ID"
    }
  }
}

Internal State Message

Topic: module/v1/ff/{DEVICEID}/{internal-TXT-DEVICEID}/state

{
  "serialNumber": "{internal-TXT-DEVICEID}",
  "orderId": "SOME_ID",
  "orderUpdateId": 1,
  "timestamp": "2023-02-02T13:57:06Z",
  "actionState": {
    "command": "CHECK_QUALITY",
    "id": "ID#1",
    "metadata": {
      "result": "PASSED"
    }
  }
}

Result Values: PASSED or FAILED.

Internal Connection Status

Topic: module/v1/ff/NodeRed/cam/connection

{
  "headerId": 2,
  "timestamp": "2023-02-20T14:59:18.900084Z",
  "version": "1.0.0",
  "manufacturer": "Fischertechnik",
  "serialNumber": "{internal-TXT-DEVICEID}",
  "connectionState": "ONLINE"
}

States: ONLINE, OFFLINE, CONNECTIONBROKEN.

Internal Factsheet

Topic: module/v1/ff/{DEVICEID}/{internal-TXT-DEVICEID}/factsheet

{
    "timestamp": "2023-02-02T13:58:06Z",
    "headerId": 1,
    "manufacturer": "Fischertechnik",
    "protocolFeatures": {
        "moduleActions": [
            {
                "actionParameters": [
                    {
                        "parameterName": "type",
                        "parameterDescription": "Type of workpiece to process",
                        "parameterType": "string",
                        "isOptional": true
                    }
                ],
                "actionType": "CHECK_QUALITY"
            }
        ]
    },
    "localizationParameters": {},
    "serialNumber": "{internal-TXT-DEVICEID}",
    "version": "1.0.0",
    "typeSpecification": {
        "seriesName": "MOD-FF22+AIQS+24V+CAMERATXT",
        "moduleClass": "internal_TXT"
    }
}

Internal Instant Actions

Topic: module/v1/ff/{DEVICEID}/{internal-TXT-DEVICEID}/instantAction

{
  "serialNumber": "{internal-TXT-DEVICEID}",
  "timestamp": "2023-02-02T13:58:06Z",
  "actions": [
    {
      "actionId": "SOME_ID",
      "actionType": "factsheetRequest",
      "metadata": {}
    }
  ]
}

OPC UA Variables

Variable Name	Description	Type
`model`	Model name	STRING
`stat__idle`	Status: System is idle	BOOL
`cmd__pick`	Command: Pick operation	BOOL
`cmd__drop`	Command: Drop operation	BOOL
`cmd__good`	Command: Good operation	BOOL
`cmd__bad`	Command: Bad operation	BOOL
`stat__pickFinished`	Status: Pick process finished	BOOL
`stat__dropFinished`	Status: Drop process finished	BOOL
`stat__badFinished`	Status: Bad process finished	BOOL
`stat__goodFinished`	Status: Good process finished	BOOL
`stat__pickFailed`	Status: Pick process failed	BOOL
`stat__moveToCameraFinished`	Status: Move to camera finished	BOOL
`cmd__moveToCamera`	Command: Move to camera	BOOL
`stat__dropFailed`	Status: Drop process failed	BOOL
`cmd__calibrate`	Command: Calibrate	BOOL
`stat__calibActive`	Status: Calibration active	BOOL
`cmd__stop`	Command: Stop operation	BOOL
`stat__calibFinished`	Status: Calibration finished	BOOL
`cmd__default`	Command: Reset to factory settings	BOOL
`stat__defaultFinished`	Status: Reset to factory settings finished	BOOL
`cmd__moveForward`	Command: Move forward	BOOL
`cmd__moveTime`	Command: Move time	TIME
`stat__moveFinished`	Status: Move finished	BOOL
`cmd__moveBackward`	Command: Move backward	BOOL
`stat__moveBackFinished`	Status: Move backward finished	BOOL
`cal__cameraTime`	Calibration time for camera	TIME
`cal__badTime`	Calibration time for bad operation	TIME
`cal__processEndTime`	Calibration time for process end	TIME
`cal__midLightGateTime`	Calibration time to position the workpiece centrally in the light gate	TIME
`stat__dropActive`	Status: Drop process active	BOOL
`stat__pickActive`	Status: Pick process active	BOOL
`stat__goodActive`	Status: Good process active	BOOL
`stat__badActive`	Status: Bad process active	BOOL
`stat__moveToCameraActive`	Status: Move to camera active	BOOL
`cal__gripperDownTime`	Calibration time for gripper down	TIME
`cal__vacuumReleaseTime`	Calibration time for vacuum release	TIME
`version`	Versioning	STRING
`cal__prePhotoTime`	Calibration time before taking photo	TIME
`cal__vacuumGenerateTime`	Calibration time for vacuum generation	TIME
`cal__preFaultCheckTime`	Calibration time before fault check	TIME
`cal__defCameraTime`	Default calibration time for camera	TIME
`cal__defBadTime`	Default calibration time for bad operation	TIME
`cal__defProcessEndTime`	Default calibration time for process end	TIME
`cal__defMidLightGateTime`	Default calibration time to position the workpiece centrally in the light gate	TIME
`cal__defPrePhotoTime`	Default calibration time before taking photo	TIME
`cal__defGripperDownTime`	Default calibration time for gripper down	TIME
`cal__defVacuumReleaseTime`	Default calibration time for vacuum release	TIME
`cal__defPreFaultCheckTime`	Default calibration time before fault check	TIME
`cal__defVacuumGenerateTime`	Default calibration time for vacuum generation	TIME

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6.5 Quality Control with AI (AIQS)

Overview

Supported Commands

Supported Instant Actions

MQTT Topics

Command Example: CHECK_QUALITY

Result: PASSED

Result: FAILED

Quality Check Process

Hardware Details

PLC I/O

Errors

Special Considerations

Complete Quality Check Flow

Related Documentation

Internal Communication (Node-RED to TXT)

Topic Structure

Internal Order Message

Internal State Message

Internal Connection Status

Internal Factsheet

Internal Instant Actions

OPC UA Variables

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6.5 Quality Control with AI (AIQS)

Overview

Supported Commands

Supported Instant Actions

MQTT Topics

Command Example: CHECK_QUALITY

Result: PASSED

Result: FAILED

Quality Check Process

Hardware Details

PLC I/O

Errors

Special Considerations

Complete Quality Check Flow

Related Documentation

Internal Communication (Node-RED to TXT)

Topic Structure

Internal Order Message

Internal State Message

Internal Connection Status

Internal Factsheet

Internal Instant Actions

OPC UA Variables