3D Assembly Inspection Mapping for Stage-Aware Quality Control

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Solution Overview

Problem

Manual inspection of complex structures, such as aircraft assembly, is prone to human error, is time-consuming, and costly, and requires extensive disassembly to identify issues, which is inefficient and costly.

Innovation Solution

An automated supervision and inspection system using a computer system that generates a three-dimensional global map of the assembly site and processes sensor data to identify the current stage of the assembly process, context, and quality report, reducing the need for human intervention and enabling efficient identification of issues without extensive disassembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual inspection is used to inspect assembly quality, then human operators can identify issues, but human error increases and inspection accuracy decreases

Engineering Contradiction:

Improveinspection accuracyVSAvoidhuman error rate

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated optical inspection system that uses sensors, cameras, and image processing algorithms to detect assembly defects. This substitution eliminates human error and significantly improves inspection accuracy through consistent, repeatable measurements and advanced image analysis capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The inspection system performs self-verification by automatically capturing images, processing them through algorithms, identifying defects, and generating inspection reports without human intervention. The system serves itself by autonomously completing the entire inspection workflow from data acquisition to defect classification.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual inspection is used to identify assembly issues, then problems can be detected, but inspection time increases and productivity decreases

Engineering Contradiction:

Improvedefect detection capabilityVSAvoidinspection speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The automated inspection system operates continuously without interruption, capturing images and processing data in real-time as assemblies move through the production line. Multiple sensors and processors work simultaneously and continuously, eliminating the pauses and sequential operations inherent in manual inspection methods.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system uses excessive computational resources and multiple redundant sensors to perform inspection tasks that would take a single human operator much longer. Parallel processing of multiple images and defect types occurs simultaneously, providing comprehensive inspection coverage far exceeding manual capabilities.

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If manual inspection is used to detect assembly defects, then issues can be identified, but disassembly requirements increase and costs increase

Engineering Contradiction:

Improvedefect identification capabilityVSAvoiddisassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The inspection system performs defect detection early in the assembly process before components are fully assembled or painted. By conducting inspection at this preliminary stage, the system identifies issues when they are most easily corrected, eliminating the need for time-consuming disassembly and repainting operations that would be required if defects were discovered later.

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If manual inspection methods are used, then inspection can be performed, but labor costs increase and operational costs increase

Engineering Contradiction:

Improveinspection capabilityVSAvoidoperational cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent replaces expensive manual labor with an automated inspection system that, while requiring significant initial investment, eliminates ongoing labor costs and reduces operational expenses through consistent, high-volume inspection capabilities. The system pays for itself by eliminating the need for multiple trained inspectors and reducing rework costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11568597B2Automated supervision and inspection of assembly process

Publication Date: 2023.01.31 THE BOEING CO

AI summary

A method and apparatus for performing automated supervision and inspection of an assembly process. The method is implemented using a computer system. Sensor data is generated at an assembly site using a sensor system positioned relative to the assembly site. A three-dimensional global map for the assembly site and an assembly being built at the assembly site is generated using the sensor data. A current stage of an assembly process for building an assembly at the assembly site is identified using the three-dimensional global map. A context for the current stage is identified. A quality report for the assembly is generated based on the three-dimensional global map and the context for the current stage.