AI-Powered Robotic Inspection: Ensuring Fuel Tank Perfection

In the highly competitive automotive industry, precision and quality are key to maintaining production excellence. Leveraging computer vision technology and AI, ThirdEye AI has implemented a digital quality inspection solution for fuel tanks leading to improved product quality and reduced cycle time.

Challenges in Automobile Manufacturing:

• Quality Control and Consistency: Ensuring the consistent quality of manufactured parts is a major challenge at the PDI.
• High Cycle Time: Reducing cycle time is essential to keep production lines efficient and making sure the part is CMM Inspected.?
• Manual Dependency: Manufacturing processes are frequently labor-intensive, which can limit scalability and efficiency.
• Limited Inspection Precision: Traditional inspection methods may not meet the precision standards required in modern manufacturing.
• Traceability and Data Management: Keeping track of inspection data and ensuring the traceability of defects over time can be difficult without advanced systems. ?
• Scalability and Flexibility: Manufacturing companies lack the flexibility to adapt to changing production demands.
• Cost Efficiency: Managing the cost of quality inspection, reducing manpower, and improving efficiency while maintaining high standards is a continuous challenge.?
• Customer Satisfaction: Poor quality control and inefficient production processes can lead to defects in the final product, negatively impacting customer satisfaction .

Quality Inspection of Fuel Tank

Scope:

1. Hole Presence Detection
2. Child Part Presence Detection
3. Hole Size Measurement
4. Hole Drift Detection??
5. Defect Detection- Sheet Metal & Welding??

Solution Approach:

Hardware:

• Machine vision cameras and laser profiler
• Robotic arm for 360 degrees scanning
• Tank placement fixture??
• Apt lighting setup (Ring-Lights)??

Software:

• Machine learning algorithm
• Real-time part inspection results
• Alert and notification on defects
• Data Visualization & Analytics
• Historical Reports to track inspection data and defect traceability
• And-on (Real-time screen with part inspection results)
• Smart factory suite integration ?

Solution Design:

Value Delivered:

Our advanced vision inspection solution has significantly transformed manufacturing processes by reducing inspection time by 45x, delivering micron-level accuracy of up to 100 microns. This enhancement has led to increased efficiency and the reduction of manual inspection cells, streamlining operations. The system's multimodal inspection capability can boost ROI by up to 2x, while ensuring comprehensive full-batch quality inspection, delivering superior product integrity and performance.

Discover how ThirdEye AI's vision inspection solutions can transform your production processes. Contact us today to learn more!?