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Edge Video AnalyticsReference design

Assembly Inspection - Missing Parts and Dimensions

A fixed camera station that checks every expected part is fitted and key dimensions are within tolerance, then gives one OK or NG verdict. The verdict goes to the PLC and the MES at the same time, and no images leave the station. It is for PCBA and small assembly lines, goods-in and dispatch checks, and auto parts or electronics plants that need a record for each part.

Manufacturing

Talk to an engineer See the hardware

Car body assembly line with doors being fitted to body shells under overhead conveyors — Photo: Anonyme, CC BY 2.5, Wikimedia Commons. Shows the setting, not this installation.

10.9 ms: Median time from capture to PLC coil on J3011, 11.2 ms at p99 (vendor benchmark)
9.81 ms: Median capture to coil time on J4012 (vendor benchmark)
11.89 ms: Median capture to coil time on R2000 with Hailo-8 (vendor benchmark)
0.9876: Detection mAP50 on the DeepPCB defect validation set, J3011 and J4012 (public test data, not missing parts)

Results reported by the design's authors on their own test setups. Yours depend on the site, so we confirm them in a pilot.

The problem

Why it matters.

Assembly stations need to confirm every part is fitted and key sizes are in tolerance fast enough for the PLC to act within takt time.

The flow

From signal to action.

01SenseStation cameraA fixed camera captures the whole board or assembly in one frame.
02DecidePart detectionAn on-site detector finds parts and defects and compares them with the expected-part template.
03DecideDimension checkPixels are converted to millimetres using a calibration marker and compared with nominal size and tolerance.
04ActPLC signalThe merged verdict is written to Modbus registers and an OK or NG coil the PLC reads.
05RecordMES recordA JSON event per frame goes to the MES over MQTT for traceability.

Deployment architecture

How it is wired.

The devices on site, what carries their data, where the decision is made and where the result goes.

01SenseOn site

reCamera Pro 2GB1 per station
IP camera (RTSP or ONVIF)1 per station

02ConnectCarries the data

RTSP
ONVIF

03DecideRuns the model

reComputer Super J3011
reComputer Super J40121
reComputer Industrial J (Orin Nano 8GB)1
reComputer Industrial R2035-121
ONNX
TensorRT

04Your systemsWhere results land

Modbus TCP
MQTT
HTTP
PLC
MES

05ActWhat happens next

PLC signal

How it works

Step by step.

01Fix the camera so the whole board or assembly stays in frame.
02Draw a box around each expected part, two clicks per box.
03Place an ArUco marker or an object of known width in the same plane to calibrate size.
04Set nominal sizes and tolerances, and choose which NG reasons apply.
05Run the line. Each frame gets one OK or NG verdict.
06The PLC reads the coil to reject parts, and the MES logs the full result.

The hardware

What goes on site.

Items we stock can go straight in the bag. Everything else we source and quote with the installation.

reComputer Super J3011Inspection host on Jetson Orin Nano 8GB1 per host, several stations possible₹84,589
reComputer Super J4012Inspection host on Jetson Orin NX 16GB with more headroom1₹1,59,389
reComputer Industrial J (Orin Nano 8GB)Fanless cabinet version of the J3011 host1Sourced on quote
reComputer Industrial J (Orin NX 16GB)Fanless cabinet version of the J4012 host1Sourced on quote
reComputer Industrial R2035-12Lower-power inspection host with Hailo-81Sourced on quote
reCamera Pro 2GBCamera and simple OK or NG checker in one unit1 per station₹32,989
IP camera (RTSP or ONVIF)Station camera for host-based setups1 per stationSourced on quote

Before you install

A rigid camera mount that will not move, re-aim or refocus after setup.
A calibration reference in the same plane as the surface being measured.
Flat parts with clear edges. Tilted parts and low-contrast edges cause errors.
Steady, even lighting over the station.
A LAN link from the host to the camera, PLC and MES. No internet is needed.

Good to know

Detection accuracy was measured on a public bare-board defect set, not on missing parts. Test the model on your own assemblies.
Dimension checks are not a certified gauge and do not replace metrology.
Moving or refocusing the camera breaks the template, which must then be rebuilt.
reCamera Pro gives OK or NG only and cannot run the missing-part or dimension checks.

How we deliver it

Paper to site, one team.

01Site surveyWe walk the site, or review photos and drawings, and agree what to measure and where each device goes.
02PilotOne lane, one line or one room first. We tune it on your conditions and agree what good looks like.
03Roll outWe supply the hardware in India with GST invoices, install it, and connect it to the systems you already run.
04SupportSpares, remote checks and model updates, with one team to call when something changes.

Questions

Asked before buying.

Can it replace our measuring gauge?

No. Dimension checks catch out-of-tolerance parts on the line, but they are not certified metrology.

Will it talk to our PLC?

Yes, if the PLC can read Modbus TCP. The verdict sits on two coils and a set of holding registers.

Does it need internet or send images out?

No. Everything runs on the host and only the verdict and results leave the station.

Want this on your site?

Tell us the site and the problem. We come back with a pilot plan and a priced hardware list.

Book a call with an engineer Write to us

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