As the trend towards electric vehicles accelerates, mission-critical high voltage vehicle systems require the next generation of quality control and inspection to ensure a zero-defect manufacturing strategy. Automation Alley member Electrical Components International (ECI), shares how they’ve built a cutting-edge software tool, KonnectAI®, that is the next generation of artificial intelligence quality inspection.
Intelligent Connected Manufacturing
In essence, at ProEV—a division of ECI powering smart, connected and electrified solutions—our focus is not on WHAT to manufacture but rather on HOW to manufacture. Consequently, we developed a computer vision inspection system that would inspect and record results for all critical parts providing instantaneous feedback to operators: KonnectAI® Quality.
This system is an in-process and final visual quality inspection system that uses state-of-the-art AI algorithms and computer vision technology to augment our quality inspection throughout our production processes. It is a unique differentiator in the electrical distribution systems industry and allows us to perform 100% in-process and final inspection for must-never-fail products. The KonnectAI® Quality system is constantly learning by using artificial intelligence to compare products to a database of thousands of images.
How It Works
KonnectAI® employs video-based AI in a continuous learning mode that feeds data frame by frame into the AI server for analysis. The algorithm divides the frame into regions and defines bounding boxes using a probability calculation for each region of the frame. The probabilities of each bounding box are weighted so that the vision model can decide a “good part” based on the whole image rather than one pixel at a time.
This efficient approach is far superior to traditional Automated Optical Inspection systems, which require hard-coded rigorous statistical calculations and static dimensional tolerances that are generally wider than necessary to allow for part-to-part variation. Each inspection image is captured by the system as a digital birth certificate.
KonnectAI® is a unique manufacturing differentiator that is designed with the operator in mind. As they assemble parts, they self-inspect their assemblies to get live inspection results and feedback. This results in higher quality parts, faster operator training, and ultimately increased confidence.
We are building tech with tech – the products and processes are being engineered together.