AI-Powered Machine Vision to Detect Assembly Errors, Missing Components, and Wiring Defects
Elevator systems rely heavily on two critical electrical assemblies:
1. The Elevator Car Operating Panel (COP)
The user-facing control interface inside the lift car
2. The Elevator Controller Panel Box
The central control unit that manages motor drives, communication, sensors, safety circuits, door controllers, emergency functions, and overall lift operation
Any assembly error, missing component, or wiring mistake inside these panels can lead to operational failures, false signals, safety hazards, and field breakdowns.
Traditional manual inspection methods are slow, operator-dependent, and prone to error—especially as modern elevator panels contain hundreds of terminals, controllers, PCBs, relays, safety modules, and wiring routes.
Intelgic's AI-driven machine vision inspection system brings accuracy, consistency, and real-time intelligence to panel manufacturing—ensuring zero-defect electrical panels for elevators.
Why Automated Inspection Is Critical for Elevator Panels
1. High Component Density
COPs and controller panels house:
- PCBs
- Terminal blocks
- Wiring harnesses
- Emergency switches
- Displays & HMI units
- Sensor interfaces
- Relays & contactors
- Power supplies
- Fuses & breakers
- Safety modules
Manually verifying every connection and component is nearly impossible without automation.
2. Strict Safety Requirements
Elevators must comply with:
- EN 81
- ASME A17.1
- ISO safety standards
- Fire & emergency safety systems
A missing wire or wrong connection can compromise passenger safety.
3. Global Quality Expectations
Elevator OEMs and maintenance companies demand zero-failure electrical systems to reduce downtime and service calls.
Our AI inspection system ensures 100% component and wiring verification with detailed digital reports for compliance and quality assurance.
Intelgic's Machine Vision Solution for Elevator Panel Inspection
Intelgic provides a complete automated inspection system powered by:
Industrial camera setup
Custom lighting for reflective surfaces
AI-based component detection
Wiring anomaly identification
OCR for label & number reading
Region-based inspection rules
Recipe creation for multiple panel variants
The system can inspect both elevator car panels and controller electrical cabinets with high precision.
Inspection of Elevator Car Operating Panels (COP)
Car panels typically include:
- Touch buttons / mechanical push buttons
- LED indicators
- Display screens
- Emergency stop switch
- Alarm button
- Intercom module
- Key switches
- Braille plates
- Back-plate circuit boards
- Wiring connectors
Intelgic’s AI inspects each of these with the following capabilities:
A. Component Presence & Placement
- - Missing buttons
- - Wrong button placement
- - Incorrect orientation
- - Misaligned display modules
- - Missing emergency switch
B. LED and Indicator Positioning
- - LED alignment
- - Lens placement
- - Incorrect LED color
C. PCB and Connector Verification
- - Loose ribbon cables
- - Missing connectors
- - Wrong connector position
D. Label & Engraving Verification
- - Floor numbers
- - Braille plates
- - Emergency labels
- - Logo and branding
- - Safety instructions
E. Cosmetic and Surface Defects
- - Scratches
- - Dents
- - Damage around button holes
- - Paint defects
- - Fingerprint marks on stainless steel
Intelgic’s solution ensures that every elevator car panel meets both operational and aesthetic requirements before dispatch.
Inspection of Elevator Controller Panel Box
The controller cabinet is the brain of the elevator system. It contains:
The controller cabinet is the brain of the elevator system. It contains:
- Main controller PCB
- Drive and inverter
- Door controller
- Safety relays
- Power supply modules
- Terminal wiring blocks
- Fuses, breakers, and busbars
- Encoder interface modules
- Communication boards
Intelgic’s AI performs detailed inspections of:
A. Component Presence & Absence Checking
- - Detects missing or extra components
- - Relays
- - Fuses
- - Breakers
- - Safety modules
- - Communication modules
- - Power supply units
B. Wiring Validation & Route Inspection
- - Correct terminal-to-terminal wiring
- - Wire color verification
- - Loose wire ends
- - Missing ferrules
- - Crossed or tangled wiring
- - Incorrect wire number labels
- - Improper routing around ducts
- - Unconnected connectors
C. Polarity & Connection Accuracy
- - +24V and GND wires
- - Sensor inputs
- - Encoder connectors
- - Drive command connections
- - Emergency braking circuit wiring
D. Orientation and Positioning
- - PCBs
- - Relays
- - Terminal blocks
- - Contactors
- - Communication modules
E. Door Controller Inspection
- - Correct module placement
- - Correct wiring between controller and door motor
- - Signal/feedback routing
- - Safety lock circuit connections
F. Gap, Alignment, and Structural Inspection
- - Door misalignment
- - Panel deformities
- - Busbar alignment
- - Poor mechanical assembly
- - Screw presence and tightness
Intelgic's AI solution ensures comprehensive inspection of all critical components and wiring in the controller panel.
Advanced Inspection Features
3. Region-Based Inspection for Better Accuracy
Intelgic divides the panel into region-specific zones:
Each zone has its own rules and logic, ensuring high accuracy in detecting errors.
4. AI-Powered Learning from Good Panels
Intelgic's system can create Golden Templates by analyzing defect-free panels.
The AI learns:
Future panels are compared against this golden standard for defect detection.
5. Automated Reporting & Digital Quality Certificate (DQC)
After inspection, the system generates:
Reports can be integrated with:
Advantages of Intelgic's Elevator Panel Inspection System
Prevents field failures
Detects assembly errors early before panels leave the factory.
Compliance assurance
Ensures compliance with global safety standards (EN 81, ASME A17.1).
Fast inspection
Reduces QC time from 20+ minutes to seconds per panel.
Objective evaluation
Eliminates human bias and fatigue in inspection process.
Micro-level detection
Detects even micro-level wiring and component anomalies.
Multi-model support
Supports multiple panel models via recipe-based inspection.
Industries & Companies That Benefit
Key Beneficiaries of Our Technology
- Elevator panel manufacturers
- Controller panel OEMs
- Lift car operating panel manufacturers
- Contract manufacturing units
- Vertical transportation companies
- Smart building OEMs
- OEMs supplying to major elevator brands
Mission-Critical Quality Assurance
Elevator car panels and controller panels are mission-critical components. Any assembly defect—whether missing components, miswiring, or cosmetic issues—can lead to serious performance failures and safety hazards.
Intelgic's AI-driven inspection system provides a powerful, automated, and scalable solution to ensure zero-defect elevator panels, with complete traceability and high production throughput.
By implementing Intelgic's machine vision technology, manufacturers can significantly improve quality, reduce rework, enhance compliance, and deliver highly reliable elevator systems.
