Several Tray Models Share One Measuring Station
A battery tray usually measures over 1.8 m x 1.5 m x 0.3 m and carries over a thousand measurement points. Trays arrive on the line conveyor, good parts are released and exceptions are blocked. This project measures them with multi-camera vision, cameras shooting together and computing in parallel, while an automatic camera layout algorithm covers several workpiece models. The result is 100 percent inline full-dimension measurement with SPC statistics, a 63-second cycle, over 100,000 parts measured and several thousand defects blocked, subject to site acceptance results.
Mixed models, not the tray, is the real problem
Measuring a single tray model is a solved problem for a multi-camera scheme. The difficulty is several trays rotating through one station. If every model change meant re-laying cameras and re-teaching, the station would become the line's bottleneck and inspection would slow production instead of protecting it.
What an automatic camera layout changes
The algorithm plans camera layout and the measurement program from the workpiece model, turning changeover from manual adjustment into a model-driven process. Model recognition triggers the layout switch, changeover time drops sharply, and parallel scheduling across models becomes possible, so the line does not need a station per model. Ask for the switch time on a real changeover, not the best case.
SPC wants the trend, not the single verdict
A single verdict blocks a bad part but cannot explain why drift started. SPC statistics measure data by point and by time and watch the trend: a few hole positions creeping upward in mean, one machine's repeatability degrading. Neither shows up in a single result, and both are obvious on a control chart. Turning after-the-fact blocking into advance warning is what the trend line buys.
How 63 seconds and 0.2 mm coexist
Measurement accuracy of 0.2 mm and repeatability of 0.025 mm are delivered inside the 63-second cycle, not measured slowly offline. Parallel capture and parallel computation supply speed, calibration and the measurement algorithm supply accuracy, and both have to be laid out at design stage. Building it fast first and accurate later does not work.
A hundred thousand parts measures stability
Over 100,000 parts measured and several thousand defects blocked say more about long-run stability than about peak speed: calibration has not drifted repeatedly, judgment has not moved with the shift, and the data link has not broken. On a mixed-model line, stability outranks a fast single cycle.
The same data serves both the release decision and SPC. Where two data sets are collected separately they eventually disagree; from one source, the trend the process engineer sees and the verdict the line sees are the same fact.
Where the scheme stops
It suits large-part lines with several models, dense points and a need for process data. With few models and a relaxed cycle, a fixed layout is more economical. If only a verdict is needed, SPC can be added later, but the interface should be reserved at design stage. Figures are subject to site acceptance results.
Questions before a mixed-model retrofit
What does the layout algorithm actually do?
It plans camera layout and the measurement program per model, giving multi-model compatibility and fast changeover in place of manual layout edits and program rewrites.
How is online SPC different from a later report?
Online statistics update the trend during inspection and warn before a batch goes bad; a report only explains what already happened.
How should 100,000 parts be read?
As evidence that the system stayed running and judging consistently across models over the long term, with several thousand defects blocked. Figures are subject to site acceptance results.