Modern automotive manufacturers face immense pressure: rising quality standards, complex production processes, and the shift to electromobility demand innovative solutions. Especially in rework – whether on painted car bodies or high-voltage batteries – manual steps are often unavoidable. But this is where errors, delays, and documentation gaps occur, costing time and money.
How can these challenges be overcome without compromising quality and efficiency?
Use Cases
Use Cases
Rework in the finish cabin
Thanks to AI-supported image recognition (so-called Car Paint Vision systems), rework-relevant defects are automatically detected after painting. Their positions are transmitted automatically to the finish area and marked by IPG laser projectors installed therein to guide manual rework and show operators exactly where to sand and polish. The projection starts automatically as soon as the car enters the marking area, and it dynamically adapts to movements of the car – regardless of whether the car is moving on a lifting table (stop & go mode) or on the line (line-tracking mode), IPG continuously marks all relevant defects precisely so that nothing is omitted.
Rework in the battery shop
When applying flame-retardant material to high-voltage batteries, shrinkage cavities or bubbles may occur in the foaming process. An intelligent image recognition system identifies these areas and transmits the data to an IPG Video. system. The video projector precisely shows the operator where to rework, thereby colour, shape, and size of the individual projections encode the defect category and size.. Also, the automatic welding process for thousands of anodes and cathodes is error-prone. AI-based vision systems analyze the welding process itself as well as the visual appearance of the weld-lines after welding. Any potentially faulty weld lines are reported and affected batteries have then to be inspected thoroughly in the rework station. IPG lasers guide the operators to quickly and reliably identify the affected weld lines among thousands of others.
Key Benefits
Key Benefits
