Project Overview
For an automotive Tier-1 supplier producing engine subframes (cradles), we automated the pre-welding component inspection using high-resolution machine vision technology.
Each engine cradle assembly requires approximately 20 distinct brackets, gussets, and fasteners to be accurately positioned before entering the automated MIG/MAG robotic welding cell.
Because structural automotive frames are heavy and safety-critical, discovering a missing component after the welding process leads to irreversible scrapping and exorbitant rework costs. 100% verification prior to welding was imperative.
Catching Defects Before Value Addition
A missing component during automated welding causes severe scrap costs. Once metal is permanently fused, remedying an omitted part requires flame cutting, grinding, or total disposal.
The crucial manufacturing tenet is clear: Do not inspect after defects become irreversible—prevent the process from initiating on incomplete parts.
The ANAVIS Solution: Automated Pre-Weld Permission Interlock
We integrated a high-resolution industrial camera and multi-region presence/absence vision inspection system at the pre-weld station.
Immediately prior to robot welding, the vision system captures the entire engine cradle body and simultaneously validates all 20 pre-defined inspection zones.
The vision system actively controls the weld cell start interlock:
- All 20 parts verified present → OK → Weld cycle trigger is released to the welding robots.
- Any single part missing or misaligned → NOK → Welding is physically locked and the operator is alerted.
How the System Works
- 01 Fixture Staging: The engine cradle enters the pre-weld inspection fixture.
- 02 High-Resolution Exposure: Industrial vision optics capture the subframe under high-intensity lighting.
- 03 Concurrent 20-Zone Analysis: Algorithms simultaneously inspect 20 individual component locations.
- 04 Presence & Seating Verification: Presence, orientation, and seating of each bracket are confirmed.
- 05 Weld Robot Interlock Release: If OK, the robot starts welding; if NOK, the cell is locked immediately.
- 06 Zero Scrap Guarantee: Incomplete subframes are prevented from advancing to permanent fusion.
