Project Overview
Objective: Design and build a miniature automated assembly line capable of sorting, coating, and inspecting electronic chip sets using integrated mechanical and AI systems. The process includes applying a spray coating solution, inspecting chips for quality, and categorizing them as good or defective based on computer vision feedback.
This project is currently in progress as part of the Manufacturing Processes course. Our goal is to replicate a scaled-down industrial assembly line that demonstrates automation, precision control, and smart manufacturing principles.
System Design and Development
The assembly line is constructed using a modular educational kit that includes conveyor systems, pneumatic actuators, sensors, and robotic arms. Our design integrates these components to form a continuous workflow — from loading raw chip sets to automated spraying, AI inspection, and sorting.
We are currently focused on:
- Designing a spray module to apply a consistent coating on each chip
- Programming motion sequences for conveyor control and timing synchronization
- Integrating an AI vision system that identifies defective chips in real time
The system will use a microcontroller interface to coordinate mechanical operations, ensuring efficient throughput and precise cycle timing.
AI and Quality Control
The most innovative aspect of this project is the use of artificial intelligence for quality assurance. A small camera module captures each chip after the spray process, and an AI model analyzes the image to determine surface uniformity, contamination, or alignment issues. The results are used to automatically direct the chip to either the “approved” or “rejected” bin using a servo-based diverter mechanism.
This step introduces machine learning-based inspection into traditional manufacturing, mirroring modern Industry 4.0 practices where automation and AI collaborate to enhance production efficiency and product reliability.
Current Progress
At this stage, our team has completed the mechanical layout design and is assembling the conveyor modules. The spraying and inspection subsystems are being prototyped, and early integration tests are underway to synchronize motion control and image capture timing. Upcoming milestones include:
- Training the AI model with real chip images
- Finalizing spray calibration and flow control
- Programming system logic for sorting and classification
- Performing full assembly line testing
Why This Project is Important
This project represents the future of automated and intelligent manufacturing. By combining mechanical engineering, electronics, and AI, it demonstrates how integrated systems can increase efficiency and consistency in industrial production. It highlights the importance of process control, real-time inspection, and smart feedback systems — critical concepts in modern manufacturing industries.
What I’ve Learned
Working on this project has strengthened my understanding of manufacturing process design, system integration, and industrial automation. I’ve gained hands-on experience in building assembly systems, synchronizing electrical and mechanical components, and applying AI tools to real engineering challenges. This project has given me a deeper appreciation for how automation and data intelligence are transforming modern engineering workflows.
Future Work
In the coming weeks, the team will finalize the control logic, integrate the AI inspection system, and perform live demonstration tests. The final stage will involve system optimization and documentation of production metrics such as throughput, rejection rate, and spray consistency.
This page will be updated as the assembly line moves from prototype to full operation.