The M&L technology approach
Automotive Rear Window Defroster Inspection with Thermal Camera
An industrial quality inspection system that examines automotive rear window defrosters with a thermal camera and automatically determines OK/NOK results by comparing thermal data with PLC measurements.
Within the scope of this project, an automated quality inspection system was developed to verify the correct and uniform operation of automotive rear window defrosters on the production line.
Thermal Imaging and Defroster Inspection
After the rear window defroster is activated, the thermal camera analyzes the temperature distribution across the glass surface. Temperature changes, heating times and thermal differences along the defroster lines are measured to detect broken tracks, uneven heating and areas that fail to deliver the expected performance.
Comparison with PLC Data
Temperature data obtained from the thermal camera is compared with current, energy consumption, operating time and process values received from the PLC. The system automatically generates an OK or NOK result for each vehicle according to predefined tolerances and quality criteria.
PLC and KUKA Robot Integration
The inspection result is transmitted to the PLC in real time. If the result is OK, the PLC sends the required command to the KUKA robot, allowing the operation to continue and the vehicle to proceed to the next production stage. If the result is NOK, the process can be stopped, the part can be directed to a reinspection station or an error notification can be sent to the operator.
Traceable and Verifiable Quality Inspection
The system can record thermal images, measured temperature values, current and energy data, vehicle or part identification information and the final OK/NOK result. This reduces the risk of human error, improves production quality and provides complete historical traceability.
- Non-contact temperature analysis using a thermal camera
- Detection of broken defroster tracks and uneven heating
- Collection of temperature, current and energy data from the PLC
- Comparison of measurement results with predefined tolerances
- Automated OK/NOK quality decision
- Real-time communication with the PLC and KUKA robot
- Recording of thermal images, measurements and inspection results
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