Cover-to-Tray Assembly


At the end of EV battery production, cover-to-tray placement must be exact and fast. This step is the last chance to ensure everything is in place, without any missing parts or debris, before sealing it up. Vision-guided inspection combines smart cameras with 2D tools (pattern matching, edge finding, measurement) or 3D profilers to capture defects or anomalies on low-contrast or reflective surfaces. This process helps ensure that batteries are correctly assembled and safe while keeping production moving.

Zebra CV60 Camera for EV Battery Pack Assembly

Automate final battery cover placement and inspection with vision, 3D sensing, and deep learning to boost yield and keep cycle times short

Automated manufacturing warehouse with a close up view of a Iris GTX camera inspecting an electric vehicle battery

Accelerate final tray inspection

Before the cover meets the tray, the Iris GTX smart camera performs rapid, in-station checks with its built-in 2D tools, including pattern matching, edge finding, measurement, and blob analysis. These features ensure the presence, orientation, and cleanliness of components within tight cycle times. Together, these tools validate assemblies and document results for quality and safety teams. Operators can leverage real-time annotated dashboards to review go/no-go decisions and efficiently monitor workflow performance.

Altiz 4200 conducting a battery inspection video screenshot

Improve inspection on tough surfaces

Low contrast surfaces, reflective metals, and uneven lighting can hide defects or contaminants. AltiZ 3D profilers use a dual-camera design to minimize scanning gaps and voids. This produces high‑fidelity 3D profiles, depth maps, and point clouds of the battery tray and cover. These 3D results pair with 2D checks to inform joint pass/fail decisions and keep cycle times stable.

Zebra IRIS GTX inspecting battery components in a manufacturing setting

Cover-to-Tray Assembly Verification

After initial inspection and validation, robotic arms precisely position covers and secure fasteners, guided by Iris GTX smart cameras for accuracy. Zebra's Aurora Design Assistant machine vision software integrates guidance, inspection, and pass/fail logic in one interface, using programmed logic to detect problems such as cross-threading and missing screws early. It logs annotated images and results for traceability and faster root-cause analysis.

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