300 Points in 200 Seconds, With Nothing Waiting in Line
An EV battery tray is a large workpiece, and in the high-complexity version it carries up to 300 inspection points. What has to be checked is not only a missing part: the state of the lower shell assembly, key dimensions, and surface problems such as scratches, deformation and stains all land on one station. The tray carries the modules directly, so assembly state and surface quality bear on pack safety, and full coverage plus cycle time are both demanded with no room to trade one for the other.
200 seconds is not fast judgment, it is no waiting
Three hundred points inside 200 seconds, subject to site acceptance results. The cycle does not come from faster single-point decisions but from the process no longer queueing: a process control module runs capture, inspection, MES upload and release or blocking as one synchronised chain instead of a serial sequence. In a serial flow each step waits for the previous one to finish completely, and the four waits add up to more than the computation itself.
Robot end or three-axis gantry depends on floor space
The capture module can sit on a robot end effector or on a three-axis gantry, and both meet the multi-angle coverage requirement. The choice follows station space and line layout: a robot end is flexible and occupies space differently, a gantry has a fixed structure and a fixed envelope. It does not change the algorithm, but it changes the cycle, because different mechanisms have different speed characteristics and the path has to be planned to each one's ability.
Defect coordinates are worth more than a pass or fail
The algorithm outputs OK or NG, defect coordinates and a class, not a binary verdict. Coordinates let rework be targeted: knowing which point and which defect type means the rework station goes straight there instead of searching the whole tray. The class routes the defect: a missing part is replenished, a scratch is dressed or judged, deformation may scrap the part. Output together, the three pieces close the exception loop.
Assembly state and surface defects judged on one line
The item list holds assembly state and key dimensions as well as missing parts, scratches, deformation and stains. The logic differs: assembly state asks whether the right part is present in the right position, which is feature comparison; surface defects ask whether the surface is sound, which is detection and classification. On one chain, feature extraction has to serve both and the point plan has to cover both distributions. The gain is a single station; the price is that algorithm complexity concentrates in one place.
When points increase, which layer changes
The architecture has three modules: capture, process control and algorithm. Adding tray models and points is handled by adding capture units and extending the algorithm model, without rebuilding the structure. That is the architectural trade: three modules cost extra interface design early and save refactoring later. The question for a buyer is where the expansion limit sits: how many capture units can be added, how far the model can be extended, and whether there is a hidden ceiling.
24/7 running and the data loop
The scheme covers a closed quality loop across production and runs continuously, day and night, matching a high-cycle line. Inspection data enters MES, and release or blocking executes automatically. If a full-check result cannot drive a production action, its value stops at the record. This is often underweighted in selection: whether the system judges correctly is one question, whether the verdict can move the line is another.
Questions on cycle and expansion
How are 300 points covered?
Through multi-angle deployment of the capture module: a robot end or gantry plans its path by point distribution. Each point is covered by camera field and angle, the whole by path planning.
Why output defect coordinates?
Because blocking is followed by handling. Coordinates target the rework and the class routes it, which together give an exception a defined next step.
What does modularity actually buy?
Expansion without rebuilding. New points add capture units, new defect classes extend the model, and the two evolve without dragging each other.