0:00 / 0:00
The high cost of assembly errors
In complex manual assembly, such as in Tier 1 automotive manufacturing, ensuring every clip, screw, and bracket is present and correctly installed is critical for final product quality and safety. The primary challenge lies in achieving 100% accuracy in high-speed environments. Traditional 3D inspection systems often create "occlusion effects," or blind spots, at critical surface junctions, which means they can't see everything, leaving room for error.
These seemingly small errors have massive consequences. Missing or incorrectly seated parts can lead to high costs from rework, an increase in warranty claims, and even potential safety recalls that can damage brand reputation. These operational bottlenecks result in significant financial losses and inefficiencies, directly impacting your bottom line and ability to compete.
The 3D assembly inspection solution
Zebra’s solution combines advanced 3D imaging and powerful edge computing to deliver a real-time inspection system that verifies the successful completion of each assembly step. This integrated approach eliminates scanning gaps with a single, cost-effective unit and drastically reduces the engineering time needed to set up and modify inspection routines, giving you a faster, more accurate quality control process.
Potential Benefits
By implementing Zebra's integrated solution, manufacturing operations can move beyond persistent quality control challenges to achieve tangible, measurable improvements in accuracy, efficiency, and cost savings.
Capture up to 59 million points per second
for rich 3D data generation with AltiZ 4200
Up to 14,000 per second profiling rates
to support high-speed scanning
Code-free development
with Aurora Design Assistant
How the solution works
Capture high-quality 3D images with a single sensor
The AltiZ high-fidelity, high-speed 3D profile sensors feature single camera or dual-camera single-laser designs that minimize scanning gaps at critical surface junctures. The AltiZ 4200 model has high-speed profiling capabilities of up to 14,000 profiles per second, capturing up to 59 million points per second to generate a rich, detailed 3D model of the component for precise inspection.
0:00 / 0:00
Get high-resolution spatial data for defect detection
The 3S Series 3D Sensors leverage structured light technology to deliver sub-millimeter resolution. This precision is crucial for identifying defects, measuring dimensions, and ensuring that assemblies meet quality standards. These sensors can accurately identify defects and anomalies on the surface of parts, such as dents, scratches, and irregularities. The sensors can handle challenging surfaces with little to no contrast or those that include reflective materials. This is due to their ability to capture detailed spatial data, enabling thorough inspection of assembly quality. The detailed spatial data collected by these sensors can be used for thorough inspection and further analysis to optimize manufacturing processes.
Build and modify inspections with ease
Zebra's Aurora Design Assistant is an intuitive software that allows engineers to build machine vision applications by simply constructing flowcharts instead of writing complex program code. It also includes ready-made project templates and application frameworks for barcode reading, measurement, color checking, and 3D dimensions for fast-track development. This drastically reduces the time and engineering cost required to set up and modify inspection routines, allowing businesses to adapt quickly to new products or assembly steps without extensive programming knowledge.
Reduce costs and errors with a reliable solution
By combining advanced 3D imaging with powerful edge analytics in a single, cost-effective solution, you can eliminate assembly errors, reduce costs, and ensure the highest level of product quality and safety.
Note:
Use case figures and savings estimates are illustrative only and may be derived from customer data, projections, or controlled testing. They do not represent guaranteed results, and actual outcomes will vary by application; customers should consult a Zebra sales representative to evaluate their specific environment.
