Advanced Cable Assembly Wire Harness Camera Inspection Color Inspection System

Product Description

Automatic Wire Harness Color Sequence & DOT Detector

The Automatic Wire Harness Color Sequence & DOT Detector is an AI-powered visual inspection system designed for 100% error-proof verification of wire harness assemblies. It automatically detects wire color sequence, cavity position, and DOT/text markings, ensuring that incorrect wiring, missing wires, or wrong insertion positions are identified before products leave the production line.

Specification

Model	KK-1503
Core Function	Automatically verifies whether the wire color order is correct, detects wrong pin positions, missing wires, reversed placement, and abnormal spacing.
Production Capacity	>1500 housings/hour
Lens Focusing	Manual focus, suitable for products with large differences; real-time image preview
Weight	kg
Color Sequence Detection	Based on color, grayscale values, AI self-learning + fuzzy AI algorithm
Automatic Position Tracking	Detects wrong PIN wires and wire spacing errors
Image Processing Speed	Real-time color processing: 12–15 inspection cycles per second

Product details

Advantages

Core Capabilities

This combines AI self-learning vision algorithms with industrial-grade hardware, enabling stable, high-speed, and accurate wire harness inspection. It supports complex layouts, random placement, wide field-of-view detection, and optional text recognition, making it suitable for automotive, new energy, appliance, and industrial wiring harness production lines.

Powered by an AI self-learning vision engine, the system can quickly adapt to different harness types without complex programming. It supports inspection speeds of up to 1500 units per hour, while maintaining high recognition accuracy even for subtle color differences.

Application

This system is widely used for final inspection of wire harnesses in  industries such as:

Automotive wiring harnesses
New energy vehicles (EV & battery systems)
Home appliances
Industrial control cabinets
Precision connector assemblies
It is typically installed after automatic crimping or insertion machines, ensuring only qualified products proceed to packaging or shipment.

After Sales Service

Standard Warranty: 12 months
Global Support: 24/7 technical assistance and spare parts supply.
Training: On-site or remote operation/maintenance training.

At our company, our core philosophy is to build reliable machines and serve customers with responsibility and long-term commitment. We believe that high-quality equipment must be supported by professional service to truly create value for our customers.

All KK Servo Terminal Crimping Machines are provided with a 12-month standard warranty, covering major mechanical and electrical components under normal operating conditions. Each machine undergoes strict inspection and testing before delivery to ensure stable performance and dependable operation.
 
To help customers quickly and efficiently use the machine, we provide on-site or remote operation and maintenance training. The training focuses on practical operation, parameter setting, and routine maintenance, allowing operators to master the machine in a short time and ensure stable, efficient production. By combining reliable equipment, professional service, and long-term technical support, we aim to build lasting partnerships with our customers worldwide.

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Why Choose Our Wire Harness Vision Detector?

This system is not just an inspection device—it is a quality assurance solution. By combining AI vision technology with industrial-grade hardware, it significantly reduces rework, prevents customer complaints, and improves overall production efficiency. With both standard and advanced models available, customers can select the most cost-effective solution without over-investment.

Processed samples

Company Profile

Packing & Delivery

FAQ

Q1: Can the machine handle random placement of wire harnesses?
A: Yes. The system supports random front and back placement, as long as the harness has clear visual feature differences. The AI vision algorithm automatically identifies orientation during inspection.

Q2: What is the maximum inspection speed?
A: The system supports over 1500 housings per hour, depending on the operator's placement speed or the feeding method of the upstream equipment.

Q3: Can it detect very thin wires?
A: The standard system supports wire diameters greater than 0.3 mm. For ultra-thin wires, we offer customized solutions after sample testing.

Q4: What is your warranty policy?
A: We offer 12-24 month warranties depending on the model, covering manufacturing defects with comprehensive after-sales support.

Q5: How does the AI self-learning system work?
A: The AI vision system learns wire color and position features during setup. Once trained, it can automatically recognize correct and incorrect sequences without complex programming, even when color differences are subtle.

Q6: What happens when a defect is detected?
A: When an NG (non-good) condition is detected, the system triggers a voice alarm, highlights the error area in red on the screen, and automatically saves inspection images for traceability.