Cluster functionality validation by automated optical inspection

This paper proposes a Normalized Cross Correlation (NCC) based solution for automated optical inspection and analysis of instrument clusters (IC) functionality. The work context resides in a research project thematic issued by the quality validation department within the local branch of one of the most important worldwide automotive manufacturers. The purpose of the automated optical inspection setup is to validate the correct functionality of the vehicle cluster during CAN communication, in different test scenarios. Following specific commands, the status of warning lights, telltales, custom pictograms, or text messages, is analyzed. Pattern matching by NCC is integrated in an NI LabVIEW application, which makes use of an industrial Basler camera and is supported by the NI Vision Development Module. The proposed application includes a custom collection of automated image analysis and processing methods, which help the core NCC approach. Supported by experimental results, an evaluation of the resulting NCC quality and usage feasibility, when applied to different visual elements present on a vehicle cluster, is presented. Once finalized, the proposed test system will be deployed for evaluation of IC functionality inside a climatic chamber. A report on different integration strategies applied with the purpose of maximizing IC optical test coverage and reducing test design effort and costs, is discussed.