AICell flush & gap

For many customers, gap dimensions and flushness are telltale signs of quality long before they even consider technical specifications.

The door closes tightly or sticks; the trim piece sits flush or protrudes; the seam runs cleanly or it doesn’t. What matters in the first impression can have serious consequences behind the scenes: If the fit is not flush, water can penetrate, air resistance increases, and the vehicle becomes significantly noisier inside.

Our solution: The AICell flush & gap measures these transitions fully automatically and across the entire process chain: in body-in-white, in the paint shop, and in final assembly. It detects glass and rubber, as well as raw and painted chrome. This generates a multitude of gap and flushness measurements per vehicle, fully automatically and within cycle time. Even where traditional sensors reach their limits: on reflective, transparent, or particularly dark surfaces. The AICell flush & gap thus covers the entire spectrum of what comes together in a modern vehicle. In practice, the AICell flush & gap inspects door joints, tailgate transitions, hoods, window mounts, and trim strips - precisely the areas where build quality can make or break the vehicle.

The real added value lies in the integration. If deviations become apparent as early as the body-in-white stage, they can be corrected there instead of accumulating as rework in final assembly. This makes process influences visible, enables closed-loop control, and significantly reduces time-consuming rework.

The customer benefit: Higher quality, increased throughput, and less rework.