Project Overview
For an automotive Tier-1 supplier manufacturing interior vehicle sub-assemblies, we engineered a high-precision camera-based automated quality inspection station integrated into the assembly lines.
The system validates post-assembly accuracy for robotically assembled components including center consoles, decorative trim panels, HVAC air vents, and sub-frame brackets.
Previously, quality inspection relied on manual visual checks by human operators. With rising line speeds and high SKU variability, manual inspection created serious risks of human error, fatigue-induced defects, and ergonomic strains.
The Risks of Manual Inspection
Even when robotic assembly functions reliably, 100% verification of clip engagement, component presence, and variant correctness is mandatory. In manual workflows:
- Defective or loose clips easily slip past tired human eyes,
- Inspection attentiveness degrades over lengthy production shifts,
- Differentiating subtle trim variations becomes prone to mix-ups,
- Rapid cycle times place undue stress on inspectors.
Such escapes inevitably lead to expensive OEM recall penalties and scrap costs.
The ANAVIS Solution: 100% Automated Vision Inspection
We integrated an industrial machine vision inspection cell directly into the post-assembly conveyor line.
As assembled parts arrive, multi-camera optics capture synchronized views across all designated inspection zones. The system analyzes clip insertion depth, presence/absence of fasteners, and correct trim seating within milliseconds.
The vision system does not simply take a photo; it definitively answers: “Is the assembly 100% correct, are all clips locked, and is the component flawless?” right on the active production line.
How the System Works
- 01 Robotic Assembly: Robots mount and snap components (vents, clips, bezels) in place.
- 02 Inspection Enclosure Entry: The part enters the illuminated industrial camera cell.
- 03 Multi-Zone Vision Analysis: High-resolution sensors examine multiple critical mounting features simultaneously.
- 04 Presence & Seating Check: Fastener engagement, component orientation, and seated tolerances are validated.
- 05 OK / NOK Instant Trigger: Real-time discrete I/O signal sends pass/fail data directly to the PLC.
- 06 Full Audit Archiving: Image logs and inspection verdicts are recorded into the MES quality database.
