Customer: General Motors (CAMI) Role: Machine Vision Control Engineer Via: Ascension Automation Solutions Location: Ingersoll, Ontario Timeline: Aug 2024 – Apr 2025

The Challenge

EV battery production was ramping fast and vision systems were a bottleneck:

  • Low throughput (~5 packs/shift)
  • Fragile inspections causing frequent downtime
  • Operator loading errors
  • Maintenance slowed by unclear alarms and HMI flows

Part 1: Production Floor Stabilization

Supported existing vision systems on the production floor, troubleshooting, optimizing, and connecting systems to factory infrastructure.

Key tasks:

  • Debugged and stabilized inspection logic to reduce false rejects — 50+ camera programs updated based on historical performance and statistics
  • Improved PLC alarms and HMI workflows for faster fault isolation
  • Connected vision systems to plant network and data logging

Improved line production from 5 packs per 8 hours to 120 packs per 8 hours.

Part 2: New Inspection Station Delivery

Designed and delivered a complete engineering kit for a new vision inspection station.

Software prototype for inspection application:

Production validation with parts on test background:

Operator loader station before camera installation:

CAD layout for camera placement, lighting, and cable routing:

Kit included:

  • Cameras and lenses
  • Lighting
  • Mechanical fixtures and mounts
  • Cables, routing, and accessories

Final station installed and running on production floor:

Results

  • Line throughput improved from 5 to 120 packs per 8-hour shift
  • Reduced false stops and faster maintenance fault isolation
  • New inspection station delivered and validated for production

Tools and Technologies

  • Matrox Design Assistant
  • Studio 5000 (Allen Bradley PLC)
  • HMI Development
  • SolidWorks (CAD layout)