AR Heat Maps for PCB Non-Conformance Visualization
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Solution Overview
Problem
Current manufacturing processes struggle to effectively reduce defects and non-conformances in products, particularly in high-volume production environments where human fatigue and lack of data aggregation hinder efficient defect detection.
Innovation Solution
The use of augmented reality (AR) devices to create and display heat maps of non-conformances on manufactured goods, such as printed circuit boards, by accessing databases for failure history data and overlaying this information onto the physical object for enhanced visualization and inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a trained operator manually inspects products using equipment like x-ray machines, then defect detection capability is maintained, but inspection reliability deteriorates due to operator fatigue and large production volumes
Solution Approach 1:
The patent creates a digital copy of the physical inspection process by capturing images of products and generating heat maps that replicate defect patterns. This digital representation allows repeated inspections without operator fatigue, maintaining detection reliability while supporting high production volumes through automated processing of multiple products.
Solution Approach 2:
The patent replaces the mechanical manual inspection process with an automated image processing system. Cameras capture product images, and computational algorithms generate heat maps and identify defects, eliminating human fatigue while maintaining inspection capability for large production volumes.
2Reliability
If current examination procedures are used without data aggregation, then inspection simplicity is maintained, but inspection effectiveness deteriorates due to lack of failure data aggregation
Solution Approach 1:
The patent merges multiple data sources including individual product images, heat maps, and historical failure data into a unified inspection system. This integration provides comprehensive failure data aggregation that enhances inspection effectiveness by identifying patterns across multiple products and time periods.
Solution Approach 2:
The patent implements feedback mechanisms where inspection results and failure data are continuously aggregated and used to improve future inspections. Heat maps from individual products feed into broader failure pattern analysis, creating a feedback loop that enhances inspection effectiveness over time while managing system complexity through automated processing.
3Measurement precision
If manual inspection methods are used, then operational simplicity is maintained, but measurement precision deteriorates due to operator fatigue and limited data utilization
Solution Approach 1:
The patent creates digital copies of inspection data through image capture and heat map generation. These digital representations enable precise measurement and analysis without the limitations of manual inspection, maintaining high measurement precision while simplifying operation through automated image processing and analysis.
Solution Approach 2:
The patent replaces manual mechanical inspection with automated optical and computational systems. Cameras and processing algorithms provide precise defect detection without operator fatigue, while the system handles complexity automatically, maintaining ease of operation for users.
Data Source
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AI summary
An image of an object is received into an augmented reality (AR) device. Information is received for identifying the object or a component associated with the object. A database is accessed to retrieve data relating to the object or the component associated with the object, and a heat map is created as a function of the data relating to the object or the component associated with the object. The heat map is displayed on a computer display device.