At Productronica 2025, Controlar will present PicAI — artificial intelligence (AI)-driven probe inspection control, the world’s first fully automated system for validating test fixtures by analyzing probe marks on printed circuit board (PCB) test points.
This patent-pending system eliminates manual fixture verification by combining dual-sided vision inspection with adaptive AI, providing an unprecedented level of accuracy, repeatability and speed in test fixture validation.
AI-powered precision for fixture validation
During ICT, FCT or other PCB testing processes, test probes leave small puncture marks on the test points
Source: Controlar (TPs) of each board. PicAI inspects these probe marks to measure deviations from the TP center with an accuracy of approximately 7 μm per pixel, identifying even the slightest misalignment, contact failure or mechanical defect in the fixture setup.
By capturing both sides of the PCB in a single, synchronized scan, PicAI provides a complete visual analysis of the test area. The system’s AI-driven software then processes the collected data to automatically verify probe conformity and generate detailed reports, offering statistical insights, trend monitoring and full traceability.
Advanced dual-sided optical system
PicAI integrates a dual-sided vision module equipped with high-resolution linear cameras and synchronized lighting, enabling precise and simultaneous inspection of the top and bottom sides of the PCB.
Its adaptive computer vision automatically adjusts inspection parameters based on PCB characteristics, such as color, size or material, ensuring reliable results while minimizing false detections. This adaptability makes PicAI suitable for virtually any PCB type used in modern electronics manufacturing.
Compact, industrial-grade design
Developed as a compact, all-in-one unit, PicAI is built from industrial-grade materials to withstand continuous operation in demanding production environments. The system includes:
• Integrated dual-sided optical module with synchronized lighting
• AI-driven software for automated analysis, traceability and reporting
• User-friendly PC-based interface for easy setup and monitoring
Its hardware and software integration enables fast, repeatable inspections with zero operator variation, supporting both production-floor quality control and R&D-level testing.
Main applications
PicAI’s versatility allows it to serve multiple stages of the electronics manufacturing lifecycle:
• Production: Acts as a critical quality gate to ensure fixture alignment with PCBs, detecting early defects before they cause rework or production downtime.
• R&D and design: Provides detailed fixture performance data, supporting faster PCB development and reducing validation time.
• Quality assurance: Offers objective, repeatable inspection data and trend-based reports to help maintain process stability and compliance.
Ultimately, PicAI replaces subjective visual checks with quantifiable, AI-assisted analysis, ensuring consistent quality standards across every production batch.
See it live at Productronica 2025
Visitors can discover PicAI in action at Controlar’s stand A1.335/9, where live demonstrations will highlight its AI-driven inspection capabilities and high-precision dual-camera architecture.
