Adaptive Workpiece Compliance Checking for Production Drift
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Solution Overview
Problem
Current quality control methods in industrial production are time-consuming and may fail to detect non-compliance in critical parts, especially when dealing with large quantities, as they rely on statistical methods that are not adaptable to production drifts and require human expertise.
Innovation Solution
A method that estimates the risk of non-compliance using a probability law associated with workpiece characteristics, allowing for self-adaptive checking by updating the probability based on actual measurements, and implementing a decision criterion to determine compliance, which can be automated and robust against production drifts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If statistical methods are used to check only a reduced sample of workpieces, then productivity is improved and quality control time is reduced, but the reliability of detecting non-compliance in critical parts deteriorates
Solution Approach 1:
The patent implements dynamic adjustment of checking intensity based on real-time production data. The system transitions from static statistical sampling to dynamic adaptive checking, where the checking strategy changes automatically according to observed production drifts and risk levels, resolving the contradiction between speed and reliability
Solution Approach 2:
The patent establishes a feedback loop where measurement results from checked workpieces are fed back into the system to update risk assessments and adjust subsequent checking strategies. This continuous feedback mechanism enables the system to maintain high reliability while optimizing productivity by focusing checks where risks are highest
2Loss of time
If traditional statistical sampling methods are applied, then quality control time is reduced, but the adaptability to production drifts deteriorates
Solution Approach 1:
The patent performs preliminary risk assessment and probability law establishment before actual checking begins. By pre-configuring the checking framework with anticipated drift scenarios and risk models, the system can quickly adapt to actual production conditions without time-consuming adjustments during quality control
Solution Approach 2:
The patent dynamically changes checking parameters such as risk thresholds, probability distributions, and checking frequencies based on observed production patterns. This parameter adaptation allows the system to maintain both speed and responsiveness to production drifts by adjusting its behavior to match actual conditions
3Reliability
If comprehensive measurement of all workpieces is performed, then reliability of compliance verification is improved, but productivity deteriorates due to increased time consumption
Solution Approach 1:
The patent applies different checking intensities to different workpieces based on their individual risk profiles. Instead of uniform comprehensive checking, the system concentrates detailed measurement resources on workpieces with higher estimated risks while using lighter verification for low-risk items, optimizing the balance between reliability and productivity
Solution Approach 2:
The patent implements a tiered checking approach where only the necessary portion of workpieces undergo full measurement. By performing partial checking on low-risk items and excessive (comprehensive) checking only where needed, the system achieves high overall reliability without the full time cost of checking every single workpiece
Data Source
AI summary
Method for checking the compliance of a workpiece, comprising the following steps: estimating a risk of non-compliance of characteristic on the basis of a law of probability associated with the characteristic; and verifying whether the estimated risk of non-compliance satisfies a decision criterion and, if so, declaring that the workpiece is compliant for characteristic; if not, measuring a value of the characteristic, determining whether or not the workpiece is compliant based on the measured value, and updating the law of probability associated with characteristic based on the measured value.