PC-Free Architecture Simplifies Deployment and PLC Integration
Georges Gauthier, product line leader for In-Sight 2D products at Cognex, told Vision Systems Design that the main engineering challenge was overcoming the usual compromise between inspection accuracy and speed. According to Gauthier, “as inspections get more advanced—higher resolution, more tools, higher quality standards—systems usually slow down. We tackled this by redesigning the architecture from the ground up, pairing high performance embedded computing with a dedicated AI engine and optimized processing pipelines. That allowed us to run more complex inspections, including advanced AI tools, at full line speed—without needing an external PC.”
Users have found the system straightforward to deploy and maintain. “Eliminating the need for a training PC and reducing the number of training images required with edge AI simplifies validation and reduces long term maintenance,” Gauthier said. “Many also appreciate the software experience is familiar—teams can get up and running quickly using the insight vision suite tools they already know.”
The dual Ethernet setup has also made integration with existing programmable logic controllers (PLCs) and automation systems seamless, he said.
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Cloud-to-Edge Software Architecture Enables Scalable, IP67-Rated Industrial Vision
The software architecture supports ongoing inspection optimization through a cloud-to-edge framework. Gauthier described this process: “The In-Sight 3900 is part of our cloud-to-edge architecture that combines the In-Sight vision suite with OneVision. Customers can manage image data and train and refine AI models centrally in OneVision, then deploy them to the In-Sight 3900 to run locally at production speed. That makes it easier to update inspections over time across multiple lines and sites—whether you are handling new products, process changes, or expanding to new lines—without disrupting ongoing production.”
Regarding durability, Gauthier said that Cognex designed this product for real-world factory conditions. The system is IP67-rated, uses industrial grade components, and has undergone extensive shock, vibration, and environmental testing. “Running everything on a single embedded platform—without an external PC—also reduces common failure points,” he said. “On top of that, our high-speed performance ensures consistent behavior—even on the fastest production lines.”
Scalability was a central consideration in the systems design. “Customers can start with a simple pilot using rule based or edge AI tools, then add higher resolution, more inspections, or advanced AI as needs grow without changing platforms,” Gauthier said. Because the In-Sight 3900 shares a unified software foundation with the broader In-Sight portfolio in OneVision, Gauthier says it's easier to scale across multiple lines, plants, or regions while keeping inspections consistent.
