AI Workpiece Inspection Feedback for Systematic Error Detection

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Solution Overview

Problem

Conventional inspection methods for workpieces, such as vehicle bodies, do not allow for a meaningful and/or 100% reliable conclusion regarding systematic production errors, limiting the efficiency and quality of workpiece inspection and production processes.

Innovation Solution

A method utilizing artificial intelligence (AI) to suggest and/or automatically implement measures for process optimization, material optimization, and production optimization through control and/or regulation interventions in a plant control system, incorporating workpiece-specific data sets and system parameters to evaluate and optimize quality, using sensors and simulations to determine and correct defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional inspection methods are used to check workpieces, then inspection can be performed manually or automatically, but meaningful and reliable conclusions regarding systematic production errors cannot be drawn

Engineering Contradiction:

Improvereliability of production error detectionVSAvoidinformation about systematic production errors

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The patent implements feedback by continuously monitoring workpiece parameters during production and comparing them against reference values. When deviations are detected, the system automatically provides feedback to adjust process parameters, enabling reliable detection of systematic production errors through continuous closed-loop monitoring rather than conventional one-time inspection

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent applies preliminary action by establishing reference value sets before production begins and pre-configuring monitoring thresholds. This preliminary preparation enables the system to immediately detect systematic errors as they occur during production, rather than discovering them after conventional inspection methods have already processed the workpieces

Inventive Principle:

Principle #10Preliminary action

2Productivity

If manual inspection is performed on workpieces, then flexibility is maintained, but inspection efficiency and consistency are limited

Engineering Contradiction:

Improveinspection efficiencyVSAvoidconsistency of inspection results

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated monitoring system that uses sensors and computational algorithms to measure workpiece parameters. This substitution dramatically improves inspection efficiency by enabling continuous monitoring while ensuring consistent measurement precision through standardized automated measurement procedures rather than variable human judgment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-service by automatically comparing measured parameters against reference values and generating inspection results without human intervention. This self-automated process maintains high inspection efficiency while ensuring consistent precision through algorithmic evaluation rather than manual assessment

Inventive Principle:

Principle #25Self-service

3Reliability

If comprehensive workpiece parameter monitoring is implemented, then quality verification is improved, but system complexity increases

Engineering Contradiction:

Improvequality verification reliabilityVSAvoidcomplexity of monitoring system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a monitoring system that can track multiple workpiece parameters simultaneously using a unified platform. The system universally applies the same measurement and evaluation methodology across different parameters and workpiece types, improving quality verification reliability while avoiding the complexity of multiple separate specialized systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If automated defect detection and correction is implemented, then production optimization is achieved, but control system complexity increases

Engineering Contradiction:

Improveproduction optimizationVSAvoidcomplexity of control system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements feedback by automatically detecting defects through parameter monitoring and immediately triggering corrective actions through the control system. This closed-loop feedback mechanism achieves production optimization by eliminating defects in real-time while managing control system complexity through automated decision algorithms that follow predefined correction protocols

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP3965952B1Method for inspecting workpieces, inspection system and processing system

Publication Date: 2026.03.25 DUERR SYST AG

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AI summary

The invention relates to a control system for controlling workpieces and to a machining system for machining workpieces, which are efficient and reliable with respect to quality optimisation, wherein for example, workpiece parameters are detected by means of an automatic control station and from there and/or from system parameters, a workpiece-specific data set is produced.