Acoustic Assembly Monitoring for Hidden Operational Steps
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Solution Overview
Problem
Conventional light-guided assembly systems are inadequate for monitoring and guiding operational steps, especially in situations where visual indicators and cameras cannot access all areas, leading to potential errors and increased costs due to inefficiencies and bottlenecks in manufacturing processes.
Innovation Solution
An acoustic and vibration detection system using sensors and processors to analyze non-visual sensory signals, such as sounds and vibrations, to confirm proper performance of operational steps, complemented by a directional light device for visual guidance and a guide system controller to provide confirmation signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional light-guided assembly systems are used, then visual guidance can be provided for operational steps, but monitoring capability is insufficient in areas inaccessible to visual indicators and cameras
Solution Approach 1:
The patent replaces the visual-based mechanical/optical system with an acoustic sensing system. Acoustic sensors detect sounds generated during assembly operations (such as clicking sounds from connector engagement) to monitor and confirm completion of operational steps, enabling monitoring in areas where visual indicators and cameras cannot access
Solution Approach 2:
The patent introduces acoustic signals as an intermediary medium to transmit information about operational step completion. Instead of relying on direct visual line-of-sight, the system uses sound waves that can propagate to sensors, allowing indirect monitoring of assembly operations in inaccessible areas
2Measurement precision
If light-guided systems are used, then operational steps can be guided, but detection of proper performance is inadequate leading to potential errors
Solution Approach 1:
The patent implements a feedback mechanism where acoustic sensors continuously monitor for characteristic sounds indicating proper performance of operational steps. The system provides real-time feedback by detecting whether expected acoustic signatures are present, allowing immediate identification of errors or incomplete operations
Solution Approach 2:
The patent uses acoustic signal characteristics (analogous to color changes) to indicate the state of operational steps. By detecting specific acoustic signatures or frequency patterns generated during assembly operations, the system can precisely determine whether steps are being performed correctly
3Productivity
If visual monitoring is used, then operational steps can be tracked, but bottlenecks and excess inventory occur due to inefficiencies
Solution Approach 1:
The patent enables continuous monitoring of assembly operations through acoustic sensing, allowing the manufacturing process to proceed without interruption for visual inspection. The acoustic sensors continuously detect operational step completion, eliminating idle time and maintaining continuous production flow, thereby reducing bottlenecks and excess inventory
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
Ensures accurate monitoring and guidance of operational steps, even in areas inaccessible to conventional light-guided systems, reducing errors and improving manufacturing efficiency by providing real-time feedback on correct performance.
Implementation Method 1
a sensor operable to detect a non-visual sensory signal generated by the action of an individual... The non-visual sensory signal may comprise an audible signal and/or a vibrational signal
Implementation Method 2
a sensor operable to detect a non-visual sensory signal generated by the action of an individual... The non-visual sensory signal may comprise an audible signal and/or a vibrational signal
Implementation Method 3
a processor operable to analyze the detected non-visual sensory signal to determine if the detected non-visual sensory signal conforms to an expected non-visual sensory signal associated with the action
Implementation Method 4
a directional light device that is selectively operable to project and target at least one indicating light to create visual indicators for the individual
Data Source
AI summary
A guidance, monitoring, and inspection system for a work area includes a non-visual sensory detection sensor, such as a microphone or vibration detection sensor, visual sensors, other sensors, and a processor. The microphone or vibration sensor is configured to sense sounds or vibrations generated in the work area during the performance of an action that are then received by a processor. The visual sensor and other sensors sense characteristics and identity of objects present in the work area. The processor analyzes the received acoustic and/or vibrational signals and compares the received signals to an expected signal associated with an operational step that was performed to confirm that the operational step has been performed, and that it has been performed properly. The processor identifies a particular operational step as defined by the visual sensors and the other sensors.