Part counting
AimTrace: automatic counting of variable components on conveyors
Automatic part counting
in three steps
High-speed acquisition
AimTrace works on conveyor belts up to 6 m/s: 200 fps acquisition is configured around the parts and how they are presented.
Artificial intelligence recognition
The artificial intelligence model, trained specifically on your parts, identifies and classifies them in about 3 ms per image.
Real-time counting
Count results reach your management system during production.
The part counting software
built for industry
Artificial intelligence model trained on your parts
The model can be trained on different part types. New product? Training depends on part variety and the available images.
Up to 6 m/s belt speed
Acquisition up to 200 fps on belts up to 6 m/s, with speed and part presentation defined together with the configuration.
Industry 4.0 integration
Counting data is available during production and connects to the MES and ERP systems you already use.
Configurable for your parts
Fasteners, mouldings, medical components and food: part shape, colour and size guide the configuration.
Real-time dashboard
Live production monitoring, automatic alerts, counting history and exportable reports — all in an interface designed for the operator.
Industrial robustness
Hardware and software designed for environments with dust and vibration and for multi-shift production.
Compare counting methods
on your process
Count estimated from weight
Weight-based counts depend on unit weight and its variability. Assess the part, tolerances and quantities when choosing a method.
The system counts the parts recognised in the images, regardless of unit weight.
Counts pulses, not parts
Touching parts or variable orientations can make a photocell signal ambiguous. Assess the sensor under actual conveyor conditions.
Artificial intelligence recognises individual parts in the images, even when they touch or change orientation, within the limits tested on samples.
Requires time and attention
Manual counting takes time and attention. Automation can free up operator time.
Automatic counting reduces recurring manual tasks and makes production counts available for review.
Manual and
automatic counting
Manual counting
- × Operator time dedicated to manual counting
- × Constant operator attention on repetitive quantities
- × Quantity discrepancies to detect before shipment
- × Quantities recorded by hand, batch by batch
- × Counting time to coordinate with line throughput
- × Count history collected separately for planning and inventory
Automatic counting
- ✓ Continuous counting across shifts, with less repetitive manual work
- ✓ Traceable per-part counts
- ✓ Batch checks to detect quantity discrepancies before shipment
- ✓ Touching or overlapping parts separated within the limits tested on samples
- ✓ Acquisition configured for line speed and operating conditions
- ✓ Count history available to MES/ERP, planning and traceability
Conveyor counting applications
Bolts and fasteners
Counting screws, bolts, washers and nuts for kit packaging. The aim is to catch kits with wrong quantities before shipment.
Small metal parts
Contract manufacturing of metal components: automatic batch-by-batch counting, delivery notes supported by traceable counts.
Logistics and industrial kits
Order preparation with multiple components: the system verifies the quantity of each part before packaging, to detect quantity discrepancies.
Technical e-commerce
Product kits for online sales: automatic counting before packing helps verify quantities before shipment.
Images
Frequently asked questions
Does AimTrace work with different part types?
Yes. The artificial intelligence model is trained specifically on your parts: fasteners, plastic mouldings, medical components, food items, metal parts. Training for a new product depends on part variety and the available images.
How long does installation take?
Mechanical installation on the conveyor belt typically takes one to two days. This is followed by artificial intelligence model training sessions — duration depends on part variety — and configuration of the ERP/MES integration. The Imago and AMCO team handles the entire process on site.
Does it integrate with our MES or ERP?
Yes. AimTrace outputs real-time counting data via standard protocols compatible with the most common MES and ERP systems. Integration is assessed on a case-by-case basis during the setup phase, based on your existing infrastructure.
Does it work with overlapping or touching parts?
Unlike a photocell, the artificial intelligence analyses every frame and can distinguish parts that touch, overlap or are oriented irregularly. The separability limit is verified on samples.
Does it require ongoing maintenance?
No. The hardware is designed for industrial environments (dust, vibration, multi-shift cycles) and the software runs autonomously. A periodic model review is recommended when new products are introduced, but no continuous operator intervention is required.
Can we try the system before purchasing?
Yes. The demo unit is installed at Imago's facility in Castegnato (BS): bring your parts and see AimTrace running live. Contact us to book a visit.
Other industrial applications
Try AimTrace with your parts
Describe the parts, belt speed and line conditions so we can assess the configuration together.
Request an assessment