AI-Based Part Identification System for Automotive Warehouses

Published on: Oct 10, 2025

Introduction
 

In large automotive warehouses, thousands of parts — from small brackets and clips to large structural components — flow in and out daily. Before these parts are labeled, stored, or dispatched, it’s critical to ensure each part is correctly identified.

Errors in identification lead to:

•  Wrong labeling
   
•  Misplaced parts
   
•  Delayed shipments
   
•  Costly returns or assembly disruptions
   

Traditional barcode-based or manual identification methods are not always feasible — especially when:

• Parts are new, unlabeled, or variant-heavy
   
• Barcodes are missing or damaged
   
• Small or similar-looking parts vary only by subtle features (hole count, size, etc.)
   

That’s where Intelgic’s Machine Vision AI Part Recognition System steps in.

Intelgic’s Solution: Visual Feature-Based Part Identification
 

Intelgic’s system uses high-resolution industrial cameras and AI-based image analysis to identify parts based on their physical and visual features — with high accuracy, even for parts with subtle differences.

Key Features

• Reads dimensions and measurements with micron-level precision
   
• Counts holes, cutouts, slots, notches
   
• Detects contours, shapes, edge profiles
   
• Matches against trained part database (CAD or sample images)
   
• Supports variant switching in real-time (auto-recipe selection)
   
• Integrates with labeling, storing, and dispatch workflows

How It Works
 

1. Image Capture
   
   Parts are placed under the camera system or pass through on a conveyor. A top-down or multi-angle imaging system captures clear images using optimized lighting.
    
2. Feature Extraction
   
   The software detects key features like:
    
   • Number and location of holes
      
   • Outer and inner contours
      
   • Overall length, width, and thickness
      
   • Presence of slots, ribs, notches, bends, threads, etc.
      
3. AI-Based Identification
   
   Live Vision AI compares the detected features with its internal trained database of parts, instantly matching the part to its ID, name, and label information.
    
4. Triggering Next Steps
   
   Based on identification, the system can:
    
   • Print & apply the correct label
      
   • Send sorting signal to robotic arm or diverter
      
   • Record identification data into MES/ERP
      
   • Flag unknown or untrained parts
      

What Features Can Be Used for Identification?

 

Feature Type	Examples
Hole Patterns	Number, spacing, diameter of holes
Outer Shape	Brackets, L-shapes, Z-shapes, irregular outlines
Slots/Notches	Cutouts or key features for differentiation
Size & Dimension	Length, width, thickness, diagonal, radius
Bend Profiles	Angle or shape after forming
Surface Text (Optional)	Engraved serials or codes (OCR supported)

Applications in Automotive Warehouses
 

• Pre-labeling stations — Accurate part ID before applying barcode/RFID
   
• Sorting before dispatch — Ensure correct shipment by matching parts to orders
   
• Storage optimization — Route to proper bins, racks, or FIFO zones
   
• Variant verification — Visually confirm part version when barcodes are identical or reused
   
• Assembly kitting — Ensure the right parts are packed for assembly line kits
   

Benefits for Warehouse Operations
 

• Zero error in labeling — Reduces wrong shipments and misplacement
   
• Faster part processing — No need for manual matching or paperwork
   
• Digital traceability — Each identification event is logged with images and metadata
   
• Works with unlabeled parts — Ideal for new arrivals, returns, or WIP
   
• Saves cost and time — Eliminates expensive identification errors
   

Integration & Customization
 

Intelgic’s solution can be deployed as:

• A standalone station with camera + AI box + label printer
   
• A conveyor-based system with automatic part detection
   
• A robotic arm-integrated station for part picking and placement
   
• An AI edge device connected to your warehouse management system
   

Supports:

• MES / ERP / WMS integration
   
• API-based communication
   
• Real-time analytics and dashboards
   
• On-prem or cloud deployment options
   

Ready to Transform Your Warehouse?
 

Intelgic helps automotive manufacturers and suppliers build smart, error-free warehouses with its AI-powered part recognition system.

Request a Demo