Case Study · Automotive

Four-Station Vision Inspection of a Car Door Handle Assembly

Four vision applications on a single runtime and one CPU unit cover a car door assembly from the first fixture loading step to the final end-of-line check, reporting OK / NOK and data matrix codes to the PLC over Profinet.
Request a Similar Application Study
Back to Case Studies

Industry

Automotive

Application

Vision system for car door handle inspection

The Application

Automating inspection of multiple child parts across the assembly line

Automotive manufacturing deals with the integration of multiple child parts such as door latches, handles and seats, and handling these with manual inspection is risky.
To overcome this, a solution was provided to automate the process using high-resolution sensors and processing units — a complete solution for the car door assembly process from start to the final step.

Key Factors

  • Installation done with four cameras at different stations
  • Single runtime licence used for all four processing stations
  • n-computing device used to operate all four monitors
  • Communication with PLC through Profinet
  • User-friendly HMI
  • High accuracy for all the variants

Performance at a Glance

One runtime, one CPU, four stations

4

Cameras installed at different stations.

1

Runtime licence used for all four processing stations.

Profinet

OK / NOK and data matrix results sent to the PLC.

Stations

How the stations work together

Each station has its own application, all running on a single runtime and a single CPU unit.

01

Station A — presence / absence

The first step: all parts are placed on the fixture and the presence or absence of the variant’s child parts is checked.

02

Station B — bell crank lever

The operator checks the presence of the bell crank lever attached to the variant.

03

Station C — position, data matrix & OCR

Operators arrange the child parts; the software inspects position and presence / absence, decodes the data matrix, and reads OCR from the bottom side.

04

Results to the PLC

All stations send OK / NOK and data matrix code results to the PLC using Profinet.

Final Result

End-of-line result on the HMI

Result screen — Station A, end of line LH side
Result screen — Station C, end of line LH side

Technology Used

Hardware behind the inspection

20 MP Basler Camera & 25 mm Lens

High-resolution imaging of the handle assembly at each station.

Aurora Vision Runtime with Deep Learning Add-On

A single runtime serving all four station applications.

n-computing Device & Hielscher Card

Operates all four monitors from a single CPU unit.

Get Started

Have a similar inspection challenge?

Share your part image, defect details, cycle time, accuracy requirements, and existing machine information. Our application team will help evaluate the right machine vision architecture for your production process.
Request a Similar Application Study
Want to connect with our Expert
close menu icon

Book an Application Consultation

Share your requirement, our expert will be in touch with you on same day