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Case Sharing: Enhancing Automotive Assembly Verification with Collaborative Robots

Client:
A renowned automotive manufacturer that produces high-quality vehicles

Application:
Automotive assembly verification

Challenge:
The automotive manufacturer faced two major challenges in their production process. First, they needed to inspect over five items, each requiring thorough and precise verification of assembly correctness and appearance. Second, determining the boundary between good and defective products proved difficult due to the ambiguity, especially under specific lighting conditions or minor discrepancies in the inspection process.

Solution:
Techman Robot’s integrated solution involved using collaborative robots (cobots) paired with advanced vision systems to automate inspection tasks with precision and efficiency.

Automotive Assembly Verification
In this application, 4 cobots and 30 external cameras were deployed to perform comprehensive assembly checks simultaneously. The automated system examined automotive appearance, interior space, and other areas to confirm correct assembly. Totaling more than 120 vision tasks are performed within 80 seconds. Specific checks included:

  1. Lighting Cover Style Check: Ensuring the correct alignment of lighting systems.
  2. Window Decoration Style Check: Verifying the appearance and proper installation of decorative elements.
  3. Anti-dust Film Check: Detecting the presence and correct application of anti-dust films.

This automated solution is also synchronized with the shop floor system to streamline inspection results directly into the manufacturer’s database.

Results:
Implementing Techman Robot’s automation solution significantly improved the efficiency and accuracy of the manufacturer’s inspection processes. Key benefits included:

  1. Reducing time used for assembly verification, ensuring checks were completed within 80 seconds.
  2. Enhanced defect detection precision leads to fewer false positives and clearer identification of defective products.
  3. Seamless integration of the cobots and external vision systems with the manufacturer’s existing shop floor and data management systems.

The use of collaborative robots allowed the client to maintain high production standards while minimizing manual labor in inspection tasks, thereby increasing overall throughput and product quality.