3D Sensor Quality Control for Volumetric Object Detection
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Solution Overview
Problem
Current quality control systems in manufacturing, such as light curtains, 'pick to light' systems, 'pick to voice' systems, and vision systems, fail to reliably verify correct operations and positioning of components due to high error rates, especially in conditions with low color differences, dynamic objects, and varying product shapes, leading to potential defects and increased costs.
Innovation Solution
A quality control system utilizing a 3D sensor system to monitor and validate operational actions within predetermined voluminous spaces, allowing for contactless detection and validation of physical objects and actions, thereby improving error detection and reducing the complexity of handling varied objects and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If vision systems are used for quality control, then detection capability is improved, but error rate increases due to false positives and inability to handle low color differences, dynamic objects, and varying product shapes
Solution Approach 1:
The patent transitions from 2D vision systems to 3D sensing by introducing voluminous spaces and depth information. The system defines three-dimensional detection zones within the working area and uses 3D sensor data to detect physical objects, thereby improving reliability in handling low color differences, dynamic objects, and varying product shapes that plague 2D vision systems.
Solution Approach 2:
The patent changes the detection parameters from color-based 2D imaging to 3D spatial positioning. By using voluminous spaces defined by coordinates (x, y, z) and depth information, the system achieves more reliable detection that is independent of color variations, lighting conditions, and object orientation, directly addressing the high error rates of conventional vision systems.
2Measurement precision
If conventional sensor systems are used to monitor objects, then measurement precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent creates a universal 3D monitoring system that can track multiple physical objects across different racks and positions using a single integrated approach. The system defines voluminous spaces that can accommodate various object types and configurations, eliminating the need for separate sensor implementations per rack while maintaining high measurement precision through 3D spatial detection.
Solution Approach 2:
The patent uses 3D sensor data to create virtual representations of physical objects within voluminous spaces. By detecting objects through their spatial coordinates and depth information rather than direct contact sensors, the system achieves monitoring accuracy comparable to conventional sensor systems while dramatically reducing device complexity and implementation cost.
3Ease of operation
If 3D sensor systems are used for contactless detection, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent divides the working area into multiple voluminous spaces, each corresponding to specific detection zones. By segmenting the monitoring area into manageable three-dimensional regions defined by coordinates and depth, the system simplifies operational implementation while the cumulative precision of multiple segmented zones maintains overall manufacturing precision requirements.
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
This system enhances process reliability and safety by dynamically checking operational sequences, reducing error rates, and providing alerts for incorrect actions, thus optimizing production and maintaining standardized workflows.
Implementation Method 1
a 3d sensor system (5) which is adapted to retrieve 3D observational data from a working area (6)
Data Source
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AI summary
According to a first aspect, the invention relates to a quality control system (1) for monitoring, controlling, safeguarding, informing, teaching and/or guiding an operator in a working area (6) of an operational process. The system (1) is coupled to a 3d sensor system (5) for observing predetermined volume objects (10) for presence of a physical object or an operational action.