The Inspection Station is an advanced quality assurance setup under the IITD-AIA Foundation for Smart Manufacturing (FSM), designed to digitally validate the final product by matching it against design specifications stored in a database. The system is a paperless, IoT-enabled solution integrated with state-of-the-art metrology instruments and industrial communication protocols.

Overview of the Inspection Station

The station enables precise quality checks using a combination of surface and dimensional measurement tools. It eliminates manual reporting, thus streamlining the inspection workflow through full digitization.

• Measurement Devices:

  • MarSurf M 310: A portable surface roughness sensor used to inspect surface finish against preset tolerances.

  • Mitutoyo 500-171-30 Digital Vernier Caliper: A precision tool to measure key product dimensions.

• Industrial Controller:

  • Allen-Bradley PLC: Controls data acquisition and manages IoT connectivity through Modbus protocol.

• Digitization:

  • No manual data entry or paper-based logs required.

  • All readings are matched against design tolerances stored in the central database.

Functional Zones of the Station

1. Measurement Area:
   Product is placed here for dimension and roughness testing.

2. Data Acquisition Module:
   Captures measurements from caliper and roughness gauge via PLC.

3. PLC Communication Hub:
   Uses Modbus protocol to transmit data from instruments to the central database for validation.

4. Evaluation Software:
   Cross-checks the acquired data with stored CAD/design specifications.

Instrumentation and Integration

• MarSurf M 310 Roughness Tester:

  • Measures average roughness (Ra) and other texture parameters.

  • Ensures surface quality within required tolerance.

• Mitutoyo 500-171-30 Vernier Caliper:

  • Measures critical linear dimensions.

  • Digital readout integrated via PLC for automated logging.

• Allen-Bradley PLC:

  • Handles Modbus communication.

  • Acts as the IoT gateway between sensors and backend systems.

IoT & Communication Protocols

The station is fully connected via Modbus-based IoT infrastructure.

• Real-Time Monitoring:
  Readings from both sensors are instantly processed.

• Centralized Database Matching:
  Measurements are validated against design profiles, ensuring consistency and eliminating human error.

• Paperless Workflow:
  No inspection sheets or physical documentation—data is recorded, analyzed, and archived digitally.