AI-Powered Machine Vision System for Detecting Defects and Foreign Objects in Automotive Door Assemblies
In automotive manufacturing, the car door assembly process is one of the most complex and sensitive stages of production. Each door goes through multiple sub-assembly steps involving wiring harnesses, switches, locks, glasses, motors, trims, and sealing. Even with highly skilled operators, manual inspection remains prone to human error — especially when parts are assembled on slow-moving hanging conveyor lines.
Common issues like missing components, improper assembly, or foreign objects trapped inside the door often go unnoticed during manual inspection, leading to customer complaints, rattling noises, warranty claims, and costly rework.
To eliminate these issues and ensure consistent quality, Intelgic offers a comprehensive Car Door Inspection Automation System — a fully integrated, AI-driven machine vision solution designed to inspect assembled doors accurately and in real-time.
Challenges in Manual Car Door Inspection
Car doors are assembled on moving hanging conveyor systems, where multiple operators work simultaneously to fit different components. Visual inspection is performed manually either at the end of the assembly station or intermittently during assembly.
This manual process poses several limitations:
Human fatigue and inconsistency
Continuous inspection under production pressure leads to oversight.
Hidden defects and foreign objects
Bolts, clips, or tools accidentally left inside the door cavity are not visible externally.
Lighting variation
Shiny painted surfaces and metal reflections make defect detection difficult by eye.
No data traceability
Manual inspections provide no digital records for quality tracking or traceability.
As a result, even a single foreign object can cause rattling, malfunction, or rejection during customer use, damaging brand reputation and increasing warranty costs.
Intelgic's Car Door Inspection Automation Solution
Intelgic’s AI-based machine vision inspection system brings precision, reliability, and automation to car door inspection.
The system combines high-resolution cameras, specialized lighting, robotic motion (optional), and AI-powered defect detection software to identify any anomalies or foreign objects inside or outside the car door.
The system can be deployed inline (while the doors are on the conveyor) or offline (in a separate inspection station) depending on the production layout.
1. Advanced Imaging and Lighting Setup
Intelgic designs a custom imaging setup optimized for car doors’ reflective surfaces and complex geometry.
Key features:
- Multiple industrial cameras are positioned to capture the inner and outer surfaces of the door.
- Specialized lighting modules (coaxial, dome, or structured lights) eliminate reflections and enhance contrast for defect visibility.
- Adjustable camera angles ensure coverage of all critical regions — including cavity openings, screw zones, weld joints, and sealing edges.
- For deeper cavity inspection, boroscopic or side-view cameras can be integrated to inspect inside the door shell.
The result is consistent, high-quality imaging that captures even the smallest abnormalities.
2. AI-Powered Defect and Foreign Object Detection
Intelgic's Live Vision AI software processes the captured images in real-time.
The software is specially trained to detect:
- Foreign objects such as loose nuts, screws, washers, clips, and tools inside the door cavity.
- Missing or misaligned parts, screws, or grommets.
- Improper assembly or incorrect part orientation.
- Surface anomalies such as dents, scratches, and weld marks.
How it works:
- The system is trained using thousands of images of good and defective doors.
- AI models learn to differentiate between normal components and unwanted objects.
- When a defect or foreign object is detected, the software highlights the region, classifies the type of defect, and generates a Pass/Fail signal.
- Results can be sent to the PLC, MES, or Quality Management System for further processing and traceability.
Intelgic’s AI engine continues to learn and adapt — improving accuracy over time as more inspection data is collected.
3. Inline or Robotic Inspection Integration
Depending on the assembly line design, the system can be implemented in two configurations:
Inline Inspection (Fixed Cameras)
- Cameras and lights are installed on both sides of the hanging line.
- The system captures images as each door passes through the inspection zone.
- AI software processes images instantly and alerts the operator if a defect or foreign object is detected.
Robotic or Motion-Assisted Inspection
- For complex door geometries, a robotic arm or linear motion system moves the camera around the door to capture multiple viewpoints.
- The system ensures full coverage without manual repositioning.
This flexibility allows Intelgic’s solution to fit both high-speed production lines and low-volume, complex assembly environments.
4. Reporting, Traceability, and Data Analytics
Each inspection cycle is logged in Intelgic’s inspection database, creating a complete digital quality record for every door inspected.
Reporting features:
Defect images
With time-stamp and position
Pass/Fail summary
By shift, operator, or batch
Defect analytics
Frequency and trend analysis
Cloud dashboard
Cloud or on-premise dashboard for production insights.
This data can be linked to Intelgic’s Digital Quality Certificate (DQC) system to provide traceable quality documentation for customers and audits.
Advantages of Intelgic's Solution
Consistent and accurate inspection, independent of human error.
Detection of hidden foreign objects inside door cavities.
Real-time Pass/Fail classification with defect localization.
Integration with existing assembly lines (inline or offline).
Reduced warranty claims and rework costs.
Digital traceability and analytics for continuous quality improvement.
Customizable system design for different door types and production speeds.
Applications
Intelgic’s Car Door Inspection Automation System can be used across:
- Passenger car and SUV door assemblies.
- EV door modules and lightweight aluminum doors.
- Truck and bus door manufacturing
- Robotic or manual assembly lines.
Car door quality directly impacts the customer’s first impression and long-term satisfaction. A single foreign object or assembly error can lead to vibration, noise, or malfunction — issues that manual inspection often fails to detect.
Intelgic’s AI-powered Car Door Inspection System replaces human inspection with a precise, automated, and data-driven approach. By combining advanced optics, industrial cameras, and deep learning software, Intelgic ensures every car door meets the highest quality and safety standards before reaching the customer.
