High-Precision Multi-Camera Vision System for a Leading US-Based Manufacturer
Overview
A US-based leading commercial vehicle manufacturer wanted to implement a real-time video-based object tracking system using multiple industrial cameras to automate quality inspection on the assembly floor. The objective was to capture and analyze live footage from three high-resolution cameras, enabling accurate comparison against CAD models for dimensional validation and improving production efficiency.
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Challenges
Absence of a high-resolution multi-camera setup to enable real-time object tracking
Inability to compare live object movement with CAD models for automated precision validation
Solution
- Designed a vision-based solution to stream RGB video from three industrial cameras for precision object tracking within a 1.5 m² area
- Enabled object tracking using marker-based algorithms (e.g., barcodes) to detect movement on a manually operated rig or fixture
- Utilized high-resolution cameras (>10MP) with 15–60 FPS, mounted on fixed posts and interfaced via USB and Ethernet for real-time streaming
- Integrated camera controls with a C++ API to support image capture triggers from an industrial PC or PLC-based system
- Compared real-time object tracking data against CAD model inputs to validate dimensional accuracy & detect deviations
- Initiated tracking via a trigger switch, & signaled outcomes through tower lamp & reset button for process acknowledgment
Outcomes
- Enabled real-time, high-precision object tracking using multi-camera input, improving defect detection accuracy and reducing manual inspection time across production lines
- Delivered a fully automated CAD model comparison and validation process, accelerating fixture setup and minimizing errors during quality checks in assembly workflows
