Inspecting Automotive Electronic Components


Automotive suppliers must verify complex wiring harnesses and electronic control modules at production speed. This is crucial because missed connectors, incorrect lengths, or poor solder joints can cause significant problems. These problems result in scrap, rework, and heightened warranty risks. Machine vision systems use multi-camera, 2D, color inspection, variant-aware recipe control, and precise measurement to confirm connector presence and orientation, wire length, and PCB features such as board seating, potting, insulation, and solder quality. Teams gain faster changeovers, digital traceability with stored images, and higher first-pass yield, which lifts throughput, keeps cycle time consistent, and proves compliance to customers.

Zebra CV60 Cameras for Automotive ECM Inspection

Streamline harness and engine control module inspections with multi-camera vision, recipe control, and traceable results that raise first-pass yield

Machine vision interface displaying automated connector inspection, measurement results, and real-time pass/fail classification within an industrial quality control workflow.

Build multi-camera inspections fast with Aurora Design Assistant

Aurora Design Assistant machine vision software enables multi-camera inspections for wiring harnesses and electronic control modules (ECMs). It orchestrates synchronized image capture, 2D color analysis, pattern matching, and precise measurement to confirm connector type, pin orientation, wire presence, and cut-to-length accuracy across variants. Calibrated tools check board seating, potting, insulation, and solder presence on printed circuit boards (PCBs). Operators see clear, accurate pass/fail results with confidence scores and annotated images in real time. Build once, then deploy across multiple lines and machines to speed changeovers and standardize best practices.

FS40 industrial smart camera performing AOI of printed circuit boards moving along a conveyor in an electronics production line. Image highlights real-time defect detection, component verification, and high-speed quality control.

Deploy on Zebra smart cameras for robust imaging

Zebra smart cameras deliver consistent images on fast-moving, space-constrained stations. For simple applications, the NS42 Smart Vision Sensor offers anomaly detection for electronics component inspection with rapid setup using only good images. For more complex inspection, the Iris GTX offers up to 16 megapixel resolution and C-mount lens options to capture small connectors and dense PCB features. Rugged industrial designs tolerate vibration, dust, and coolant mist, while compact form factors and straightforward mounting simplify deployment at harness boards and ECU test cells.

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