Proposal / 01 of 12
The proposed system checks assembly sequence and final connection condition. It records results and evidence before the unit proceeds to the next station.
PGQ19 battery assembly station.
Enlarge imageProposal / 02 of 12
Inspection, operator guidance and traceable records for the assembly station.
| System element | Proposed function |
|---|---|
| Camera inspection | Check assembly sequence and final connection condition. |
| Operator Kiosk | Display the current item, progress, results and NG reasons. |
| Engineering & Quality | Manage model packages, items, programs, station settings and inspection history. |
| Programs by battery type | Select the inspection sequence for the identified battery type. |
| Inspection records | Store results, timestamps, images and assembly events. |
| Station outputs | Send OK/NG results, affected items and steps to the next station, with andon indication. |
| Testing and operating guidance | Test the system on the actual process and provide operating instructions. |
The final configuration follows point mapping, the customer SOP and station interface requirements.
Proposal / 03 of 12
Enlarge imageHold the battery in position.
Capture assembly activity and connection features.
Show instructions and inspection results.
Select the program by battery type.
Run inspections and store evidence.
Proposal / 04 of 12
Enlarge image| Zone | Entries | Planned checks |
|---|---|---|
| Module-row | 8 | Sequence, seating and locking |
| BMS | 12 | Sequence and connection condition at mapped points |
| HVIL / interlock | 7 | Sequence and installation criteria for 5 QT and 2 interlock entries |
| Busbar | 5 | Sequence and agreed visual connection criteria |
Drawing review maps entries to physical inspection points. Locking criteria apply where relevant.
Enlarge image
Enlarge image
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Enlarge imageBlue highlights come from the source CAD. The interlock detail does not show the entire HVIL inventory. Camera inspection does not measure torque, HVIL continuity or BMS electronic function.
How it works / 05 of 12
Place the battery in the fixture.
Wait for identification.
Scan the identifier according to the agreed procedure.
Select the program and create a session ID.
Follow the item shown on the display.
Trigger inspection when hand activity enters the zone.
Complete the manual installation.
Check the assembly event and final condition.
Continue or follow the NG guidance.
Record the result and determine the next step.
Follow the final inspection result.
Store evidence before sending the station output.
All steps must follow the SOP sequence. No manual capture is required for each connector.
Image activity triggers inspection without a PLC part-present signal. Hand entry or exit alone does not confirm completed installation.
How it works / 06 of 12
| Status | Meaning |
|---|---|
| IN PROGRESS | Assembly or inspection is still in progress. |
| OK | Required sequence and condition checks pass, and results and evidence are stored. |
| NG | A sequence violation or nonconforming condition has been confirmed. |
| NOT VERIFIED | Evidence or inspection capability is insufficient to complete the assessment. |
MR-02 remains incomplete when MR-03 is installed.
Installing MR-02 afterward does not clear the violation. Authorized personnel determine disposition according to the SOP.
An unrecorded installation event leaves the sequence unverified. An item awaiting installation is not automatically NG. NG means nonconforming.
How it works / 07 of 12
Connection InspectionIllustrative dataActual item positions follow drawing review.
MR-02 not installed
Item IDs and sequence are illustrative.
Expected item: MR-02
Two different session examples. The CAD image illustrates the inspection area.
How it works / 08 of 12
Program ConfigurationIllustrative dataProgram version v1.0 / illustrative sequence
Program excerpt / 3 items
| Step | Item | Model package | Model version |
|---|---|---|---|
| 01 | MR-01 | Connection Model A | v1.0 |
| 02 | MR-02 | Connection Model A | v1.0 |
| 03 | MR-03 | Connection Model B | v1.0 |
Programs order physical items. One model package can serve multiple items after validation at each point.
Configuration changes are tested before use in subsequent sessions.
Engineers configure items and test changes before use.
Quality personnel review records and record unit disposition.
The kiosk and Engineering & Quality are separate applications. Active sessions retain their starting configuration.
How it works / 09 of 12
Ready-to-use inspection
package and version.
Area, SOP criteria
and one assigned model.
Ordered items
for a battery type.
| Example step | Item | Model package | Model version |
|---|---|---|---|
| 01 | MR-01 | Connection Model A | v1.0 |
| 02 | MR-02 | Connection Model A | v1.0 |
| 03 | MR-03 | Connection Model B | v1.0 |
The model must support all required item criteria.
Reordering items does not, by itself, require a new model.
Three illustrative items explain the relationship. The scope remains 32 CAD inventory entries. Shared models require validation at each point.
How it works / 10 of 12
Each session records battery type, program version, items, timestamps, condition and sequence results, and image evidence. The battery serial number is recorded separately when available.
Inspection HistoryIllustrative dataPGQ19 / program v1.0 / illustrative sequence
Affected item / MR-03
ILLUSTRATIVE EVENT LOG
CAD illustration; inspection image not yet available.
Linked to the original session. Rechecking the final condition does not clear the original sequence NG.
Illustrated record relationship; no completed rework result is claimed.Final condition
A final image supports the connection condition assessment.
Assembly sequence
Timestamped events and related images or video clips.
Results and evidence are stored before outputs are sent. Authorized manual release is recorded separately, with the reason and responsible person.
Delivery / 11 of 12
Inspection matrix and final-condition criteria.
Test eight connectors and the application workflow.
Test BMS, HVIL and busbar inspection.
Station outputs, records and operating instructions.
| Measure | Target |
|---|---|
| Precision and recall for locked/unlocked classification | Each ≥98% |
| Detection of deliberately introduced faults | ≥95% |
| False rejection of conforming units | ≤2% |
| Response after the hand leaves the zone | ≤1 second |
Proposed targets, not project test results. Test methods, sample sizes and acceptance criteria will be agreed before testing.
The production sequence across zones follows the customer SOP. Test results will be reported by zone and fault type.
Delivery / 12 of 12
Assembly sequence and condition inspection,
with operator guidance and traceable evidence.
| Topic | Agreement required |
|---|---|
| Inventory and drawings | Mapping of the 32 entries to inspection points. |
| SOP and final condition | Mandatory sequence and completion criteria for each item. |
| Identification and programs | Barcode format, battery type and serial number where available. |
| Station integration | Result interface and evidence storage requirements. |
| NG handling | Authorized roles, unit disposition and reinspection procedure. |
These agreements define the system configuration and test plan.
