3D Sensed Data Alignment for Model-Based Object Inspection
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Solution Overview
Problem
In-person inspections of three-dimensional objects are time-consuming, prone to human error, and limited by the volume of data that can be captured and processed, leading to inefficiencies and high costs, especially when comparing objects over time.
Innovation Solution
A system and method for autonomously collocating and interpreting sensed data using multiple sensors to associate data points with physical space on objects, comparing them to pre-fabricated models, and identifying similarities and differences between inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If in-person inspection with specialized metrology equipment is used, then measurement precision is improved, but productivity deteriorates due to time-consuming manual processes
Solution Approach 1:
The patent replaces manual inspection processes with an automated system using sensors, processors, and computer vision algorithms. The system captures images and sensor data, processes them through machine learning models, and automatically generates inspection reports, eliminating the need for manual measurement and analysis while maintaining high precision.
Solution Approach 2:
The patent creates digital replicas of physical objects through photogrammetry and point cloud generation. Multiple images captured from different angles are processed to create accurate 3D digital models that can be analyzed without physical contact, preserving measurement precision while enabling automated high-speed processing.
2Loss of information
If multiple sensors capture data from multiple positions, then information completeness is improved, but device complexity worsens
Solution Approach 1:
The patent employs a multi-functional sensor apparatus that integrates multiple sensor types (cameras, LiDAR, depth sensors) into a single device. This universal device can capture various types of data (visual, spatial, depth information) simultaneously, improving information completeness without proportionally increasing system complexity.
Solution Approach 2:
The patent merges data from multiple sensors and multiple capture positions into unified point cloud representations and 3D models. The processing system integrates heterogeneous data sources (images, depth maps, spatial coordinates) into a cohesive digital model, managing complexity through unified data structures and processing pipelines.
3Measurement precision
If large volumes of inspection data are stored and processed, then measurement precision is improved, but loss of time worsens due to data transmission and processing delays
Solution Approach 1:
The patent performs preliminary processing of inspection data during capture, generating initial point clouds and identifying key features in real-time. This preliminary action reduces the volume of data requiring subsequent detailed analysis, maintaining measurement precision while minimizing processing delays.
Solution Approach 2:
The patent segments the inspection process into distinct stages: data capture, preliminary processing, detailed analysis, and report generation. Each stage processes only the necessary data subset, enabling parallel processing and reducing overall time while preserving the precision required for final measurements.
Data Source
AI summary
A method for collocating sensed data of one or more three-dimensional objects, the method comprising: autonomously collocating, with a processor, a first data set resulting in a first collocated data set, which may correspond with one or more first three-dimensional working models of the one or more three-dimensional objects, respectively; and autonomously interpreting, by a processor, the first collocated data set, by comparison to one or more pre-fabricated three-dimensional models, to determine an identity of the one or more three-dimensional objects associated with the one or more first three-dimensional working models or to determine the state and/or operating conditions of three-dimensional objects.