Control Panel Box Inspection Using AI and Machine Vision

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Microscopic Inspection Automation
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Control Panel Box Inspection Using AI and Machine Vision

Modern industrial systems rely heavily on control panel boxes to house and manage critical electronic components. Ensuring the accuracy, completeness, and quality of these panels is vital to operational safety, efficiency, and compliance. Intelgic provides an advanced AI-powered control panel box inspection solution that leverages machine vision cameras, robotic imaging systems, and intelligent image processing software to inspect each panel down to the finest detail.

Why Control Panel Box Inspection Is Critical

Control panel boxes consist of densely packed electrical and electronic components, such as:
  • PCBs (Printed Circuit Boards)
  • Relays and switches
  • Terminal blocks
  • Circuit breakers
  • Connectors and wiring harnesses
  • Microcontrollers and custom IC chips
  • Electrial Wires with different colors
  • Various switches,
  • Motors and drivers
  • DIN rails and other smaller components.
Any missing, misplaced, or defective component can lead to:
  • System failure or breakdown
  • Electrical short circuits or fire hazards
  • Costly rework or product recalls
  • Compliance and warranty issues

Intelgic’s Comprehensive Inspection Solution

Intelgic’s AI-driven inspection system is designed to ensure that every control panel is complete, correctly assembled, and defect-free—regardless of size or complexity.

Key Features and Capabilities

Component Presence and Placement Verification

  • Detect missing, misplaced, or reversed components.
  • Verify that each part is installed in the designated location.

Counting of Components

  • Count all small electronic parts (capacitors, resistors, ICs, terminals, etc.).
  • Compare against a known “golden template” or BOM (Bill of Materials).

Inspection of Wiring and Cable Connections

  • Verify wiring routes and ensure correct cable connections.
  • Detect loose wires or cross-connected terminals.

Component Identification Using OCR

  • Read text, numbers, serial codes, and chip IDs printed on PCBs or components.
  • Validate that the correct chips or modules (e.g., microcontrollers, ICs) are installed in the correct locations.

PCB Defect Detection

  • Inspect the PCB for surface defects such as:
    • Cracks and scratches
    • Burn marks and soldering issues
    • Delamination and discoloration
  • AI models detect both surface and structural anomalies.
Control Panel Box Inspection

Advanced Imaging Technology

To accommodate control panels of various sizes, shapes, and layouts, Intelgic integrates a range of hardware and imaging technologies:

Multi-Camera Configuration

  • Multiple area scan or line scan cameras are installed to capture high-resolution images from different angles and depths.
  • Suitable for mid-sized to large control panels.

Robotic Rail and Motion Syste

  • For large or deep cabinets, cameras and lighting modules are mounted on robotic rails or motorized stages that move in X, Y, and Z directions.
  • Controlled by PLC or AI logic to ensure full coverage and optimal focus for every section of the panel.

Specialized Lighting

  • We use industrial lighting system to ensure even and unirom lighting
  • Ensure minimized reflections
  • Shadowless lights with visibility.

Intelgic Live Vision AI Software

At the heart of the solution is Live Vision AI—Intelgic’s proprietary software platform designed for real-time image processing and defect detection.

Software Capabilities:

  • Model Training: Customizable for different product types and layouts.
  • Template Matching: Compare current panel image with the golden reference image.
  • Zone-Wise Analysis: Detect and localize issues within specific zones or layers.
  • Defect Reporting: Includes defect coordinates, defect type, and annotated images.
  • Recipe Management: Maintain inspection templates for different panel variants.
Benefits of Automating Microscopic Inspection

Applicable Industrie

Intelgic’s control panel box inspection solution is industry-agnostic, designed to meet the needs of multiple sectors where control panel integrity is critical:

Elevator & Escalator Systems

Industrial Machinery & Automation

Automotive Manufacturing

Electrical and Power Distribution

Building Management Systems (BMS)

Medical Devices and Equipment

Aerospace and Defense

Construction Equipment

Telecommunication Infrastructure

Energy and Utilities

Benefits of Intelgic’s Inspection System

  • Zero-defect delivery by catching all visual errors before the panel leaves the factory
  • Reduced inspection time using automated high-speed scanning
  • Scalable to any panel size or layout
  • Easy integration with PLCs, MES, or ERP systems
  • Automated recordkeeping for traceability, warranty compliance, and quality audits
Benefits of Automating Microscopic Inspection

Intelgic’s AI-powered control panel box inspection system transforms how manufacturers validate the assembly and quality of control panels. With precision imaging, advanced AI, and flexible mechanical design, the system ensures that every component is present, correctly placed, and defect-free. This solution not only enhances product quality but also reduces rework, improves traceability, and safeguards industrial safety.

If you’re looking for an inspection solution that adapts to your panel designs and scales across industries, Intelgic’s Live Vision AI system is the complete, customizable platform you need.

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