Application of Atonm Color Sensor CL2 in Missing Component Detection for Automotive Air Outlets

I. Project Background

Automotive air outlets are assembled from a variety of small components (such as paddles, grilles, decorative strips, etc.). In automated production, component missing issues are liable to occur, which directly impair product functions and brand reputation. Traditional manual visual inspection is characterized by low efficiency, poor accuracy and high cost, making it unable to keep pace with the high-speed production rhythm of assembly lines. Enterprises are thus in urgent need of an automated inspection solution to resolve this pain point.

II. Inspection Principle & Scheme Design

(1) Core Inspection Principle

The equipment pre-saves the standard color parameters of all key components of a complete air outlet in advance. During inspection, if the preset color signal is identified, the component is determined to be present; if the target color signal is not detected, the system will immediately judge that the component is missing, output an alarm signal and trigger subsequent handling actions.

(2) Overall Scheme Design

1.Sensor SelectionThe Atonm Color Sensor CL2 Series is selected. It can accurately capture subtle color differences, fully meeting the color recognition requirements of air outlet components. With a high-speed response time of 200μs, it can match the high-speed production rhythm of the assembly line. In addition, its 8-channel output design supports simultaneous recognition of 4 colors, eliminating the need for repeated deployment of multiple devices.

2.Installation LayoutAn inspection station is set up downstream of the assembly station. The probes of two CL2 sensors are respectively aligned with the key component areas of the air outlet and fixed by brackets. Combined with the small light spot feature of the adaptive probes, the system ensures that the light irradiates the detection surface vertically, avoiding errors caused by reflection angle deviation.

3.System IntegrationThe sensors are connected to the PLC control system, alarm devices and sorting mechanism. When a missing component is detected, the sensor outputs a signal to trigger the buzzer and warning light for alarm; at the same time, the sorting mechanism removes the defective products. Qualified products are released, and the assembly line operates continuously.

III.  Application Results

The automated inspection system reduces the need for 6 full-time inspectors, saving an annual labor cost of 300,000 yuan. Meanwhile, after-sales maintenance costs are reduced by 80%, yielding remarkable economic benefits.

With advantages of high-speed response, high-precision recognition and flexible installation, Atonm CL2 Color Sensors have accurately addressed the pain point of missing component detection for automotive air outlets, achieving optimization of both efficiency and cost. This solution can be rapidly extended to defect detection scenarios of other automotive components such as instrument panels and door interior trim panels, further improving the level of production intelligence.