3D Coordinate Mapping for Paint Defect Repair
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Solution Overview
Problem
Automated identification and location of paint defects on moving assembly lines is challenging due to high production pace and human error, with existing vision technologies unable to effectively translate defect information to operators for repair in a new coordinate system.
Innovation Solution
A method and system using an optical device, laser projector, and photogrammetry system to establish a three-dimensional coordinate system within a work cell, allowing for precise identification and visualization of defect locations, enabling operators to focus on repairs without initial defect location and providing feedback on task completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If vision technology is used to identify paint defects, then defect identification capability is improved, but the ability to translate defect location to operators in a new coordinate system deteriorates
Solution Approach 1:
The patent introduces a coordinate transformation system as an intermediary between the vision technology detection space and the operator work cell space. This intermediary component receives defect data in one coordinate system, transforms it mathematically to the new coordinate system, and delivers it to operators, thereby resolving the information loss problem while preserving defect identification capability
Solution Approach 2:
The patent replaces manual coordinate transformation and defect location mapping with an automated computer-based system. The mechanical/manual process of translating defect locations between coordinate systems is substituted with electronic data processing and mathematical transformation algorithms, eliminating information loss during translation
2Ease of operation
If operators manually locate and identify defects, then flexibility in repair operations is improved, but productivity and consistency deteriorate due to human error and slow pace
Solution Approach 1:
The patent implements preliminary automated defect identification and location marking before operators begin repair work. The system pre-locates all defects, assigns unique identifiers, and prepares repair instructions in advance, allowing operators to immediately begin repairs without time-consuming manual inspection, thereby increasing productivity while maintaining operational flexibility
Solution Approach 2:
The patent establishes a feedback loop where the system continuously monitors repair progress, updates defect status, and provides real-time guidance to operators. This feedback mechanism ensures consistency in repair standards while maintaining operator flexibility through adaptive instructions, and significantly speeds up the overall process by eliminating re-inspection cycles
3Reliability
If automated defect identification is implemented, then inspection consistency is improved, but system complexity and cost deteriorate
Solution Approach 1:
The patent designs the automated system to perform multiple functions: defect detection, coordinate transformation, location marking, operator guidance, and repair verification. By making the system universal and multi-functional, the patent reduces the need for separate specialized equipment for each task, thereby maintaining inspection consistency while limiting the increase in overall system complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables operators to efficiently repair paint defects by providing clear, visible indicators of task completion, reducing human error and improving defect tracking, allowing multiple operators to work simultaneously without sequential dependency.
Implementation Method 1
An optical device identifies an item on the surface of a workpiece
Implementation Method 2
The controller then signals the light projector to scan a beam of light onto the surface of the workpiece identifying a disposition of the item disposed upon the surface of the workpiece
Implementation Method 3
The light projector or the photogrammetry system generate a three-dimensional coordinate system within the work cell
Data Source
AI summary
A method of identifying an item on a surface of a workpiece is disclosed. An optical device identifies an item on the surface of a workpiece. An item identification system includes a light projector and a photogrammetry system. One of the light projector and the photogrammetry system generates a three-dimensional coordinate system within the work cell. One of the light projector and the photogrammetry system identifies a location of the surface of the workpiece within the three-dimensional coordinates system. The controller calculates geometric location of the item on the surface of the work piece in the three-dimensional coordinate system as identified by the optical device. The controller signals the light projector to project a beam of light onto the surface of the workpiece identifying a disposition of the item disposed upon the surface of the workpiece.