In electronics manufacturing, printed circuit boards (PCBs) are often fastened automatically by robots—for example, in control units, battery packs, or other assemblies. To ensure precision and reliability, the robot needs accurate information about the PCB's position and the exact location of each screw hole. A vision sensor handles this task by confirming the PCB is correctly positioned and providing the robot with precise screw point coordinates.

The modules installed in the high-voltage battery must be electrically connected to each other, and the connectors must be applied accurately to avoid damage.

In the production of electronic components, components must be screwed together. Automating this process helps screw as many components as possible in the shortest time without compromising quality. To achieve a short cycle time, screwing operations are performed continuously while components move along the conveyor belt, ensuring a fast and efficient process

In many applications, connector harnesses with colour-coded pin positions are used to make electrical connections between different components.

During the assembly and production of electronic parts, connectors must be attached to printed circuit boards, and wires or cables are inserted in the connectors. The aim of the application is to check whether a connector has been fully inserted into the socket.

In modern production facilities, where traceability and quality control are essential, reading OCR and DMC codes on components plays a key role. These codes are used not only for identification, but also to ensure complete traceability of products and components throughout complex manufacturing processes. A reliable vision system must not only recognize OCR and DMC codes, but also compare them against each other.

In wire harness production, new cables are attached to existing ones using adhesive tape. These connection points must be consistently detected by sensors throughout the cable manufacturing process.

On many PCBs, thermal paste ensures optimal heat transfer between electronic components and a heat sink. Incorrect application of thermal paste can lead to damage to the components. To prevent this risk, a camera should check the thermal paste for presence, position and correct geometry.

In modern manufacturing, the need for seamless component traceability (Track-and-Trace) continues to grow. Data Matrix Codes (DMCs) have emerged as one of the most reliable methods for identification and traceability. The goal is to scan the Data Matrix Code on each component, guaranteeing precise product processing and flawless serial number management.

Every day, countless packages are shipped around the world. To ensure each one can be tracked reliably, shipping labels must be read accurately, often containing barcodes, QR codes, or DataMatrix codes. A vision sensor is used to automatically identify and decode these labels. However, proper setup is required before the sensor can perform this task effectively, and this setup process is often the first obstacle.

Regardless of whether the wiring is automated or manual, it is necessary to check the connector latches. Improperly latched connectors can trigger a subsequent defect and cannot be corrected due to the battery pack design.

In electronics manufacturing, processes often require the handling of very delicate or particularly small components. When placing a control chip, as in this example, no gripper errors may occur, as damage must be avoided under all circumstances.

Inside the battery pack there are wiring harnesses which need to be fixed with fastening clips. Failure to engage the clamps correctly can result in damage to the cables or rattling noises during subsequent driving operation.

During the assembly, packaging and production processes in different sectors, parts must be collected from trays for individual work steps. 

The protection of external electrical connections and coolant lines requires the manual application of protective caps. Without protective caps, accidental contact with high-voltage connections or damage as well as contamination may occur, so their presence must be monitored.

Almost every electrical component has plug connections with pins. During production, these pins can be bent or incorrectly positioned due to various influences, such as mechanical stress. This can lead to damage to the component. Therefore, careful inspection of the pins for early detection of possible damage is important.

A robot is tasked with picking components from a flexible feeding platform. The position of the objects may vary. A vision sensor can identify and relay the exact position of the part to the robot.

Throughout the production process, a large quantity of data is generated that has to be monitored and checked. The operator must be able to consult, manage and evaluate this data easily in order to identify and implement any necessary modifications to the process.