Preassembly Inspection of Power Train Components


Before final assembly, power train lines must confirm that gears, shafts, clutches, and related parts are present, positioned, and defect‑free. Manual checks can slow production flow and miss subtle issues. In‑line vision verifies positions, reads features, and validates part identity without stopping the conveyor. 3D imaging measures adhesive bead width, height, and profile, and inspects catalyst substrates. The result is faster builds, higher first‑pass yield, stable throughput across variants, and traceable quality with accurate, real‑time data showing a clear audit trail from cell to line.

Zebra Fixed Scanners being assembled in the factory

Bring preassembly accuracy to power train lines with 2D vision for part verification and 3D bead measurement for sealing quality

Zebra GTX Smart Camera for Automotive Assembly Verification

Automate 2D inspections on the line

Zebra Iris GTX smart cameras automatically confirm 2D features are correctly formed and defect-free at the point of build. They measure gear and shaft positions in transmission bodies, verify fastener presence, and check gear teeth for nicks and burrs. Measurement tools allow users to set desired tolerances for critical dimensions, whilst pattern matching and optical character recognition (OCR) tools enable the setup of presence and absence checks for critical features and identifiers. Once deployed, the system triggers pass/fail outputs to the line, preventing bad parts from advancing and standardizing quality across shifts and model variants.

Zebra AltiZ 3D Profiler for Automotive Bead Inspection

Measure beads and catalytic elements in 3D

Zebra AltiZ 3D profile sensors mounted on robots or fixed stations measure sealant and adhesive beads to gaskets and other powertrain components in motion, capturing width, height, and profile even on low‑contrast surfaces. Zebra Aurora Design Assistant software defines bead paths, compares profiles to tolerances, and associates results to each workpiece ID for traceability. When a skip or thin area appears, the system flags the cell for adjustment or stops the station with clear operator guidance, protecting downstream assembly and reducing rework and leaks.

Software Aurora Design Assistant Bead Inspection Screenshot

Guide robots and inspect beads with 3D software

Aurora Design Assistant machine vision software provides a comprehensive portfolio of vision tools and premade templates to accelerate automotive inspection application development. The platform connects to major robot and PLC ecosystems over industrial protocols, unifying guidance, inspection, and data logging configuration. The software also provides a single integrated and hardware-agnostic environment for the development of inspections across both 2D and 3D vision, which means it will work for both Zebra and third-party hardware.

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