AI-Based Detection of Welding and Lug Defects in Automotive Rim Production

In modern automotive manufacturing, the reliability of each component is essential. One critical area is the presence of welding and lugs on rims. Any absence or imperfection in this area can lead to significant functional failures and compromise safety during the final assembly process. Ensuring that these issues are detected in real-time is no longer a luxury but a necessity.

The Challenge: Incomplete Welds and Missing Components

The automotive manufacturer was experiencing the following problems:

• Missing or incomplete welds in lug areas

• Presence-absence errors in lug attachment

• Assembly-line failures due to undetected defects

  
  

These issues not only led to assembly problems on the customer side but also increased the risk of return penalties and safety concerns.

The Dataguess Solution: Project Studio in Action

Dataguess deployed its Project Studio platform to implement an advanced AI-based detection system for weld and lug verification. Here's how the project was structured:

1. Data Collection & Labeling:

   • Operators manually identified and labeled rims with welding defects during the regular quality control (QC) process.

   • A wide range of error types and defect positions were recorded to ensure robust model training.

2. Model Training & Test Validation:

   • AI models were trained using this diverse dataset to recognize welding defects and lug presence issues with high accuracy.

   • Models were tested under varying conditions, accounting for different lug positions and lighting variations.

3. Real-Time Deployment:

   • Once deployed, the system immediately began identifying and flagging rims with welding or lug-related errors.

   • Operators could then correct the welds in real time, before the parts moved further down the production line.

     
     

Project Results: Safer Rims, Smoother Assembly

The AI system significantly reduced the number of welding and lug errors reaching the customer. Manual oversight was minimized, and incomplete welds were proactively corrected by operators on the line, eliminating costly rework and potential returns.

Key Benefits:

• Real-time detection of incomplete or missing welds

• Accurate lug presence-absence control

• Prevention of customer-side assembly failures

• Reduced operational risk and cost

  
  

Let Dataguess Ensure Your Rims Meet the Highest Standards

Don't leave critical weld and lug inspections to chance. Trust Dataguess Project Studio to bring AI precision and consistency to your automotive production line.

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