1.Project background

This customer is a core supplier of domestic automotive interior electronics, and its central control panel products are supplied by many new energy vehicle companies. With the upgrade of smart cockpits, the size of central control panels is getting larger and larger, and the requirements for appearance and interaction are getting higher and higher. The original manual assembly inspection mode has many missed appearance inspections and low functional testing efficiency. Poor appearance and interaction failures have become major customer complaints. There is an urgent need to upgrade the automated production line.

2. Core pain points

1. Panel appearance requirements are extremely high, and defects such as scratches, color difference, and uneven gaps rely on manual visual inspection, which results in low efficiency, high missed inspection rate, and frequent customer complaints;

2. There are many functional test items such as touch, display, knobs, buttons, etc. Manual testing is cumbersome, inefficient, and prone to missed tests;

3. Scratches and bruises are prone to occur during the assembly process, resulting in low appearance yield of finished products and high rework costs;

4. Multi-size and multi-model panels are produced on the same line, manual changeover and adjustment are slow and the flexibility is insufficient.

3. Overall solution

Guangke Industry has customized a clean assembly and testing complete line solution for the central control panel's high appearance requirements and complex functional testing. The clean workstation design is used to avoid appearance damage, and it is equipped with a 3D visual appearance inspection system and a fully automatic functional test unit to realize the automation of the entire process from component assembly to final inspection of finished products, fully ensuring appearance quality and functional reliability, and adapting to multiple models of flexible production.

4. Solution core configuration

1. Clean protection assembly unit

The core assembly station adopts a clean and dust-proof design, and the contact surface of the tooling is anti-scratch to avoid scratches and bruises during the assembly process, ensuring the appearance yield from the source.

2. 3D visual appearance inspection system

High-precision 3D vision + AI algorithm comprehensively detects surface defects such as scratches, pits, chromatic aberration, gap uniformity, button flatness and other appearance defects, and accurately identifies defects, replacing manual visual inspection.

3. Fully automatic functional test unit

Automatically complete touch sensitivity test, display effect test, knob button life and feel test, backlight uniformity test, communication function test, all items are automatically judged, and the results are traceable.

4. Modular flexible design

Tooling and testing procedures can be quickly switched to adapt to the co-line production of central control panels of different sizes and configurations, meeting the product iteration needs of multiple models.

5. Full-process traceability management

A traceability code is bound to a single product, and assembly, appearance inspection, and functional test data are retained throughout the process, supporting accurate problem traceability and digital quality optimization.

5. Project implementation results

1. Appearance inspection efficiency increased by 60%: 3D visual inspection replaces manual visual inspection, with fast inspection speed and full coverage. The efficiency is increased by 60%, and the detection misjudgment rate is less than 0.2%;

2. The finished product yield rate is significantly improved: with anti-scratch assembly and full-process inspection, the finished product appearance and functional yield rate is increased to 99.3%, and rework costs are significantly reduced;

3. Functional testing is comprehensive and reliable: all projects are automatically tested, the problem of missed tests and misjudgments is completely solved, and the after-sales customer complaint rate of the product is reduced by 80%;

4. Enhanced flexible production capacity: supports the co-line production of multiple types of center control panels, shortens model change time by 65%, and can quickly adapt to new models.

6. Customer value and evaluation

After the production line was put into production, the appearance quality and functional stability of the central control panel have been greatly improved, and it has been highly recognized by many new energy vehicle companies, helping customers successfully win supporting orders for multiple flagship models. The stability of automated testing also helps customers get rid of their dependence on skilled quality inspection personnel, making production capacity expansion more flexible.