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This work presents new generation of online inspection systems, developed and deployed in automotive assembly plants, to provide 100%, online evaluation of automotive processes and subassemblies. The presented systems are thermal-vision based, with capability to provide two dimensional, spatial and temporal temperature acquisitions, and are equipped with novel processing routines for data collection, conditioning and processing. Specific systems are presented in the stamping presses, paint curing practices, with inspection schemes designed to provide an efficient manufacturing sequence, through (1) pro-active diagnosis routines to monitor the process performance, while inspecting the product, (2) focusing on the error detection rather than defect detection routines, and (3) utilizing closed loop, feedback communications.

This work presents two implementation modes of thermal imagery systems, to evaluate automotive painted structures mainly car-shells and fuel containers. The non-intrusive evaluation is done through passive (static) and active (dynamic) thermography systems. Passive implementation employs built-in heat agitation sources in the process-chain, while the active system utilizes an external, controlled perturbation sources. The coated structures are evaluated from two perspectives; protective aspect, which include coat thickness, adhesion and pinholes. Aesthetics inspection focuses on contaminants detection and layer uniformity. The work discusses each case study through theoretical modeling and simulation to explain the detection theory, and further present laboratory testing results under controlled conditions. The actual system implementation is also discussed, with the challenges identified and the mitigation procedures shown.