Comprehensive Guide: 16 Key Inspection Scenarios from Parts to Complete Vehicles

Smart automotive manufacturing is experiencing rapid development. SinceVision’s solutions cover all scenarios in intelligent automotive manufacturing. 

1. Car Door Gap and Flushness Inspection

3D Laser Profiler - SRI Series

Project  Challenges: High labor inspection costs, inconsistent measurement standards, and difficulty ensuring vehicle appearance quality and assembly precision.

Solution: A robotic arm equipped with SinceVision’s integrated 3D laser profiler sensor enables collision-free inspection at greater distances, achieving 0.015mm flushness precision and 0.09mm gap precision, thus improving assembly quality and safety.

Project Advantages:

 · Integrated design saves 50% of installation space.

 · Multi-camera networking technology reconstructs inspection scenes in 3D.

 · Anti-vibration performance meets IEC international standards for stable imaging and reliable data.

2. Finished Tire Quality Control

3D Laser Profiler - SRI Series

Project  Challenges: Defect recognition delays, low efficiency in manual re-inspection, and excessive workstation occupancy.

Solution: During tire rotation, online inspection is performed on vulcanized tires using multi-camera networking for comprehensive, high-speed image acquisition.

Project Advantages:

Different models of integrated 3D laser profilers are selected based on precision needs.

Accurately identifies various defects.

High-speed scanning reduces CT and significantly cuts down on manual re-inspection workload.

3. Inner Tube Rubber Strip Width and Thickness Inspection

3D Laser Profiler - SRI Series

Project  Challenges: Difficulties in real-time high-precision monitoring of black rubber strip width and thickness during inner tube production; lack of effective incoming material quality control.

Solution: SinceVision’s integrated 3D laser profiler with top-and-bottom camera installation monitors inner tube rubber strip dimensions. The 660nm red laser ensures clear imaging, and the UFP processor provides high-speed data processing for efficient inspection and output.

Project Advantages:

Advanced UFP processor for synchronized data calculation and output.

660nm red laser provides clear imaging of black rubber.

Wide temperature adaptability (0~50°C) for industrial environments.

4. Tire Building Machine Belt Layer Overlap Inspection

3D Laser Profiler - SRI Series

Project  Challenges: Difficult to precisely inspect belt layer overlap, leading to potential tire assembly quality issues and safety hazards.

Solution: SinceVision’s integrated 3D line laser profile sensor is installed above the drum, detecting belt layer joint status during drum rotation. The red laser wavelength is suitable for imaging black materials.

Project Advantages:

Sampling frequency up to 13kHz, average scan speed up to 3600mm/s.

660nm red laser stably identifies dark belt layer surfaces.

825mm wide field of view, one-scan imaging without stitching.

5. Steering Wheel Flatness Inspection

3D Laser Profiler - SRI Series

Project  Challenges: Ensuring the steering wheel’s geometric shape meets design standards for driving comfort and assembly precision.

Solution: SinceVision’s integrated 3D laser profiler sensor achieves 0.03mm high linearity flatness control, adapts to V-shaped product postures, and supports one-scan coverage of height differences with adaptive brightness adjustment for varying colors.

Project Advantages:

High linearity for smooth surface assurance.

Enhanced depth of field for large height differences.

Adaptive brightness for different lighting environments.

6. Flat Wire Motor Insulation Slot Paper Detection

3D Laser Profiler - SRI Series

Project  Challenges: Need to identify defects such as collapsed, damaged, or deformed insulation paper to prevent insulation failure caused by flat wire pin insertion.

Solution: Top-mounted SinceVision integrated 3D laser profiler scans rotating products at 180mm/s in one image. Compared to traditional 2D vision, 3D inspection provides height data for improved accuracy.

Project Advantages:

Integrated algorithms and rotational calibration for realistic reproduction.

3D point cloud data for multi-angle defect recognition.

Supports differential encoder triggering for stable signals and fine imaging.

7. Flat Wire Motor Rotor Magnet Quality Inspection

3D Laser Profiler - SRI Series

Project  Challenges: Difficult to accurately identify small defects such as pits and cracks on the rotor magnet surface; traditional inspection is easily affected by strong magnetic fields.

Solution: SinceVision’s integrated 3D laser profiler with high-density X-axis point cloud design captures defects ≥0.5*0.5mm, resists magnetic interference, and supports differential encoder triggering for precise, detailed imaging.

Project Advantages:

3200-pixel X-axis density for stable micro-defect recognition.

Strong anti-magnetic interference for clear imaging in strong magnetic fields.

Differential encoder triggering reduces equipment complexity and cost.

8. Corrugated Water-Cooled Plate Film Thickness Inspection

Confocal Displacement Sensor - SCI Series

Project  Challenges: Need to ensure coating/plating thickness on corrugated water-cooled plates meets design standards for corrosion resistance and thermal conductivity.

Solution: SinceVision’s confocal displacement sensor provides non-contact thickness measurement for transparent materials, real-time thickness output, 0.0006mm accuracy at 240mm/s.

Project Advantages:

High-energy white light for stable detection through plastic film.

Accuracy deviation<2μm.

Max mirror angle ±60°, compatible with complex corrugated surfaces.

9. IGBT Heat Sink Pin Height Inspection

3D Laser Profiler - SRI Series

Project  Challenges: Ensuring IGBT heat sink pin height meets design specs for assembly precision and heat dissipation.

Solution: SinceVision’s integrated 3D laser profiler uses image stitching for online height and flatness inspection, compatible with various colors and pin shapes.

Project Advantages:

Adaptive exposure for multi-color products.

0.006mm height precision, 0.003mm flatness repeatability.

Integrated design saves over 50% of installation space.

3200-point X-axis density for clear point cloud details.

10. Oil Filter Gasket Height Inspection

3D Laser Profiler - SRI Series

Project  Challenges: Need to fully capture gasket shape for height and damage inspection to ensure sealing performance.

Solution: SinceVision’s integrated 3D laser profiler fuses depth and height images for clearer surface imaging.

Project Advantages:

Adaptive laser brightness for multi-color gaskets.

High-density X-axis point cloud for ≥0.25×0.25mm defect focus.

Built-in 2.5D profile detection for easy result extraction.

11. Air Conditioner Fan Wheel Bottom Height Difference Detection

Laser Displacement Sensor - SGI Series

Project  Challenges:  Need to detect fan wheel runout during rotation to prevent noise, vibration, and component wear.

Solution: Side-mounted SinceVision laser displacement sensor at the fan wheelbase provides max runout feedback at 88kHz, supporting multiple communication protocols.

Project Advantages:

7μm accuracy reduces false detections.

88kHz sampling enables up to 700mm/s detection at 0.01mm intervals.

Integrated design saves 50% of installation space.

12. Seat Back Line Scan Inspection

3D Laser Profiler - SR Series

Project  Challenges: Need to ensure seat back positions meet design parameters for occupant support, comfort, and safety.

Solution: SinceVision’s split 3D laser profiler uses dual cameras for side-by-side scanning, restoring the seat’s true shape in one high-precision scan.

Project Advantages:

Anti-vibration hardware for smooth imaging.

Ultra-large inspection range for easy image analysis.

13. Seat Back Contour Inspection

Laser Displacement Sensor - SD Series

Project  Challenges: Traditional methods face complex image processing, low efficiency, poor adaptability, and cannot meet dynamic inspection standards.

Solution: Multiple SinceVision point laser displacement sensors fixed in place measure height data for contour calculation.

Project Advantages:

EtherCAT module for synchronized multi-camera data collection.

Rectangular spot for hole/drop scenarios.

Button and digital display for easy adjustment and improved efficiency.

14. Automotive Gear Surface Defect Detection

3D Laser Profiler - SRI Series

Project  Challenges: Need to address edge defects and damaged teeth in gear production to improve efficiency and quality.

Solution: SinceVision’s integrated 3D laser profiler enables real-time online inspection via product rotation, efficiently identifying defects.

Project Advantages:

Multi-layer fusion of point cloud and brightness for clear details.

Interleaved laser and gear lines avoid high reflectivity.

High resolution for stable detection of ≥0.2mm jagged defects.

15. Brake Pad Flatness and Height Difference Inspection

3D Laser Profiler - SRI Series

Project  Challenges: High manual inspection costs, risk of missed detections, and lab instruments can only sample, not fully replace manual inspection.

Solution: SinceVision’s integrated 3D laser profiler covers the entire product surface in one scan, achieving 0.005mm flatness repeatability to accurately screen defective products and control friction material thickness and pad-disc fit.

Project Advantages:

Built-in 2.5D profile measurement for synchronized output.

0.01mm flatness error control reduces missed detections.

High dynamic light adaptation for multi-material imaging.

16. Vehicle-to-Road Height Detection

Laser Displacement Sensor - SGI Series

Project  Challenges: Manual inspections are slow and tiring, leading to missed or incorrect detections, with road cracks and potholes not found or addressed in time, affecting maintenance decisions.

Solution: Two SinceVision point laser displacement sensors mounted at the vehicle front collect data at 88kHz during driving, supporting multiple communication protocols.

Project Advantages:

Vibration and shock performance meets IEC standards for stable data.

1.2 million data storage for high-speed read/write.

IP67 protection for harsh environments like humidity and dust.

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