Adaptive Quality Thresholds for Variable-Parameter Processing

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Solution Overview

Problem

Existing quality assessment systems for processing operations, such as welding, fail to automatically adapt quality criteria when processing parameters are deliberately changed during the process, leading to inaccurate quality assessments.

Innovation Solution

The method involves automatically considering changes in processing parameters by adapting quality parameter threshold values in real-time, ensuring that the quality assessment reflects the actual processing conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If quality parameter threshold values are fixed based on optimal processing conditions, then quality assessment is simple and consistent, but the assessment becomes inaccurate when processing parameters are deliberately changed

Engineering Contradiction:

Improvequality assessment accuracyVSAvoidquality assessment system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The quality parameter threshold values are made dynamic by automatically adapting them to the actual processing parameters during operation. The system continuously monitors processing parameters and adjusts threshold values in real-time, transforming the static threshold system into a dynamic one that responds to changing processing conditions, thereby maintaining assessment accuracy without requiring complex manual intervention

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements feedback by automatically detecting changes in processing parameters and using this information to adapt the quality parameter threshold values. The feedback loop continuously compares actual processing parameters with reference values, calculates deviations, and automatically adjusts the threshold values accordingly, eliminating the need for complex manual recalibration while maintaining high assessment accuracy

Inventive Principle:

Principle #23Feedback

2Measurement precision

If quality parameter threshold values are manually adjusted for each processing parameter change, then assessment accuracy is maintained, but time consumption and operational complexity increase

Engineering Contradiction:

Improvequality assessment accuracyVSAvoidtime for quality assessment

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The quality assessment system performs self-service by automatically detecting processing parameter changes and adapting its own threshold values without requiring manual intervention. The system autonomously monitors processing parameters, calculates deviations from reference values, and automatically adjusts quality parameter threshold values, eliminating time-consuming manual adjustments while maintaining high assessment accuracy

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system stores reference processing parameters and corresponding quality parameter threshold values in advance. When processing begins, the system has pre-prepared the baseline data needed for automatic adaptation, allowing it to quickly respond to parameter changes without time-consuming manual setup or calculation of threshold values

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If fixed quality criteria are used for all processing conditions, then the assessment system is simple to operate, but it produces unjustified rejections or positive assessments when processing parameters change

Engineering Contradiction:

Improvequality assessment operation simplicityVSAvoidquality assessment reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system automatically changes the quality parameter threshold values based on detected changes in processing parameters. Instead of using fixed criteria, the system dynamically adjusts the assessment parameters to match the actual processing conditions, maintaining both operational simplicity and assessment reliability by eliminating the need for manual parameter changes while ensuring accurate evaluation under varying conditions

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system uses feedback from processing parameter monitoring to automatically adjust quality criteria. The feedback mechanism ensures that the quality assessment remains reliable under changing conditions while keeping the operation simple, as the system autonomously adapts its criteria without requiring user intervention or complex manual adjustments

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12203949B2Method for quality assessment of a processing operation with adaptive quality assessment parameters adapted to changes in processing parameters

Publication Date: 2025.01.21 FRONIUS INT GMBH

AI summary

In a method and device for assessing the quality of a processing operation, a workpiece with specific processing parameters is processed along a processing trajectory. The (X), wherein the processing result is measured by at least one sensor and at least one sensor signal is recorded and at least one quality parameter is determined based on at least one sensor signal and the at least one quality parameter is compared with quality parameter threshold values to assess the quality of the processing result. During the assessment of the processing operation quality, changes made to the processing parameters from target values during the processing are automatically taken into consideration, in that, instead of the quality parameter threshold values, quality parameter threshold values adapted to the changes in the processing parameters are determined, and the at least one quality parameter for assessing the quality of the processing result is compared with the adapted quality parameter threshold values.