Lens Compatibility and Angle Control on Gearshift Knobs with Dataguess Inspector

In automotive component manufacturing, ensuring the correct lens type and precise alignment on gearshift knobs is vital. Any assembly error, whether in angle or component selection, can lead to batch recalls, customer dissatisfaction, and compromised vehicle quality. With Dataguess Inspector, this delicate process is automated and secured through AI-driven inspection and PLC integration.

The Challenge: Precise Lens Assembly Control

The customer faced the following issues:

• Inaccurate lens angle on the gearshift knob

• Incompatible lens types assembled on the same platform

• Risk of faulty parts progressing through the production line

• Quality problems and potential wrong-batch shipments

  
  

The Dataguess Solution: Inspector Ensures Accuracy

Dataguess Inspector was deployed to enable precision assembly control through real-time AI validation and seamless integration with factory automation systems.

1. Data Collection & Labeling:

   • Multiple scenarios were captured from the production floor, including both correct and incorrect lens placements.

   • The data was labeled and used to train models that could distinguish between lens types and identify angle misalignments.

2. Live Integration with PLC:

   • Dataguess Inspector was integrated via the Siemens S7 protocol, receiving a trigger from the PLC to begin inspection.

   • If any error is detected, the system immediately blocks the part from proceeding.

   • The part remains locked in position until the correct lens and angle are verified.

3. Fail-Safe Assembly Validation:

   • Real-time feedback prevents human error during assembly.

   • Operators receive instant alerts and cannot move forward until compliance is ensured.

     
     

Results: Error-Free Assembly and Consistent Quality

Thanks to the Dataguess Inspector, misassembled gearshift knobs are now a thing of the past. Assembly errors are identified and corrected in real-time, leading to flawless product delivery and zero incorrect batch shipments.

Key Benefits:

• Accurate lens type and angle verification

• Immediate feedback and part-locking mechanism via PLC

• Prevention of incorrect shipments

• Full traceability and compliance in gearshift knob assembly

  
  

Drive Manufacturing Precision with Dataguess Inspector

Avoid costly recalls and ensure flawless component assembly with Dataguess. Our Inspector solution brings precision, safety, and reliability to every step of your production.

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