This paper describes the design and implementation of a novel inspection system for detecting defects on car bodies based on artificial vision, implemented in Ford Factory at Almussafes (Spain). The system is based on the principle of performing a lightning sweeping with static imagining system, which caus- es shadows surrounding defects when merging consecutive im- ages, coined as defect augmentation phenomena. As a result, we can detect millimetric defects of 0.2mm diameter or greater with different shapes which were very hard to detect with exist- ing technology without that phenomena. The project has gen- erated two PTC patents, the first one protects the defect aug- mentation phenomena, while the second protects the industrial system itself. The main innovation of this industrial project is the development of a system that improves in almost 100As a consequences, it reduces the number of invalid vehicles, energy consumption, saving painting which also implies a significant cost reduction. It also improves working conditions for workers by reducing ocular fatigues.
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