Case Study: MO.S.A.I.C. achieves automated, 24/7 brake-disk defect detection and removal across 200+ models with Zebra (Aurora Design Assistant & Concord PoE)

MOSAIC Refines Quality Assessment with Vision System

MO.S.A.I.C., a global robotics and industrial-automation team serving the automotive sector, needed a more reliable way to catch sand and sintering residue left on sand-cast brake disks and remove non-optimal units from the production line. The existing human-inspection process was inconsistent across operators and could not efficiently handle the short cycle times or the wide variety of disk models.

The team deployed Zebra’s Aurora Design Assistant software with Zebra Concord PoE frame grabbers, nine Teledyne DALSA cameras, custom lighting and PLC integration to capture and analyze every disk angle in-line. The custom vision system detects subtle defects invisible to the naked eye, standardizes inspection across 200+ disk models, reliably ejects bad units, and delivers repeatable 24/7 quality control while speeding up throughput.

MO.S.A.I.C

Marco Pistilli

IT Engineer, Machine-Vision System and Software Developer