Manual and semi-auto assembly after placement is where missing, wrong, and reversed parts creep in—and they often surface only at the finished unit. This plant ran DaoAI AI-AOI for high-takt full inspection after assembly, stopping problems at the board level.
After placement, industrial control boards still go through extensive through-hole and assembly steps: connectors, headers, jumpers, heatsinks, and shielding cans are fitted by hand or semi-automatically, and omission, wrong model, reversed orientation, and not-fully-seated parts creep in easily. Such defects may not affect the board's appearance but surface only at unit assembly or field use, where rework is costly. The prior manual final check, limited by speed and attention, could only spot-check key locations and never covered everything.
The plant deployed DaoAI AI-AOI for completeness inspection of the assembled board: the model judges, at each key location, whether the component is present, the model correct, the orientation consistent, and the part fully seated. With APDT positive-sample learning, each board type is modeled on a few good boards, and semantic false-call filtering avoids treating allowable assembly tolerance as a defect. The system runs inline full inspection at high takt, upgrading a once spot-checked step to board-by-board coverage; a new board type switches over in five minutes with zero code, no line stop or reconfiguration.
Inspection coverage
- Missing parts: are connectors, headers, jumpers, heatsinks all present
- Misload: is the model / polarity / orientation correct
- Not seated: are through-hole parts fully inserted
- High-takt inline full inspection replaces manual spot-checks of key locations
Catch an assembly omission before the board leaves the line, not at the finished unit.
After go-live, combined detection of missing parts and connector misloads reached over 97%, assembly defects were caught at the board level, and related defects flowing to the unit stage fell markedly; inline full inspection replaced manual spot-checking, easing both the labor burden and the miss risk at the final-check station.
FAQ
What problems are prone to occur in manual and semi-automatic assembly after SMT?
After SMT, manual and semi-automatic assembly are prone to problems such as missing parts, wrong parts, and reverse installation. These defects often appear in the whole machine. The original manual final inspection has incomplete coverage and high rework costs. DaoAI AI-AOI can solve them.
What can DaoAI AI-AOI detect?
DaoAI AI-AOI can perform integrity inspection on the whole board after assembly, covering missing parts (such as whether connectors are complete), wrong installation (whether model/polarity/direction is correct), and non - in - place (whether plug - in parts are installed in place).
What are the effects after the launch of DaoAI AI-AOI?
After the launch of DaoAI AI-AOI, the comprehensive detection rate of missing parts and wrong/omitted connector installation exceeds 97%. Assembly - related defects are intercepted at the board level. It replaces manual sampling inspection, reducing the manpower pressure and oversight risk at the final inspection station.