Abstract: Misfitting and missing installation of waterproof and sealing components in automobile manufacturing easily lead to vehicle water leakage and reduce product reliability. This paper builds a visual inspection system based on programmable logic controller. Combined with the zero-defect concept for automobile production, the system links vehicle identification, body positioning and visual inspection units, optimizes algorithms and camera modes, and captures operators' part picking actions in real time to realize 100% active error prevention during operation. Compared with traditional camera inspection, this system raises the detection accuracy from 94.46% to 99.89%, cuts the response time from 2.9 s to 1.2 s, and reduces the installation and commissioning time from 8 h to 2 h.

Key words: production and manufacture; zero defect zone; visual inspection; PLC; proactive fault prevention

摘要： 在汽车制造中，防水堵漏部件错装、漏装易造成整车漏水，降低产品可靠性。文章基 于可编程逻辑控制器搭建视觉检测系统，结合汽车生产零缺陷理念，联动车辆识别、车身定 位与视觉检测模块，优化算法与相机工作模式，实时采集员工取件动作，实现作业全过程百 分百主动防错。该系统相对传统视觉检测方案，检测准确率由 94.46%提升至 99.89%，响应时 长由 2.9 s 缩短至 1.2 s，安装调试时长由 8 h 缩减至 2 h。

关键词: 生产制造；零缺陷区域；视觉检测；PLC；主动防错