AR Inspection of 3D Printed Sand Molds for Hidden Channel Cleaning
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Solution Overview
Problem
The manual and time-consuming process of inspecting and cleaning complex 3D structures, such as 3D printed sand molds, for unbound sand and defects, which can lead to part failures and require restarting the manufacturing process, necessitates a more efficient and scalable solution.
Innovation Solution
An augmented reality (AR) system that aligns a virtual model with the physical 3D structure, allowing for real-time tracking and visualization of cleaning tools within hidden channels, enabling effective inspection and cleaning by displaying occluded areas and tracking tool movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual cleaning and inspection methods are used for complex 3D structures, then the process can be performed with simple tools, but the time required increases significantly and completeness cannot be verified
Solution Approach 1:
The patent creates a digital twin (virtual model) of the physical 3D structure that mirrors its geometry exactly. This digital copy is then used to track and visualize the cleaning tool's position and to verify cleaning completeness, allowing operators to see which areas have been cleaned and which remain, thereby reducing time and improving verification accuracy
Solution Approach 2:
The patent replaces manual mechanical inspection methods with an automated optical tracking system using augmented reality. The system uses cameras and computer vision to track the cleaning tool's position automatically, substituting human visual inspection and manual verification with automated digital tracking and visualization
2Reliability
If complex molds with hidden channels are cleaned manually, then the mold structure can remain intact, but the cleaning process becomes extremely time-consuming and difficult to verify
Solution Approach 1:
The patent uses a digital twin of the mold with hidden channels to track the cleaning tool's position within the complex geometry. The virtual model allows operators to visualize tool position and cleaning progress within hidden channels that would be impossible to see directly, maintaining mold integrity while dramatically improving cleaning efficiency and verifiability
Solution Approach 2:
The patent introduces an augmented reality interface as an intermediary between the physical cleaning process and the operator's perception. The AR system overlays virtual information (tool position, cleaning status) onto the physical view, enabling operators to monitor and verify cleaning within hidden channels without physical access, thus improving productivity while preserving mold integrity
3Reliability
If thorough inspection is performed to detect all defects and unbound sand, then part quality improves, but the inspection time and complexity increase
Solution Approach 1:
The patent uses a digital twin of the mold as an inspection aid, overlaying virtual channel geometry onto the physical mold view. This allows inspectors to see where channels should be and compare with actual cleaning status, improving part quality through more thorough inspection without requiring complex additional testing equipment
Solution Approach 2:
The patent enables the inspection system to use the mold's own digital model and existing optical tracking infrastructure to perform verification. The system leverages the already-created digital twin from manufacturing and the same cameras used for tool tracking, allowing the system to self-verify cleaning completeness without adding separate complex inspection equipment
Data Source
AI summary
A method and system provide the ability to examine a three-dimensional (3D) structure. A physical 3D structure is acquired. A digital model of the 3D structure is acquired in an augmented reality (AR) system. The digital model is calibrated to match the 3D structure. The digital model is projected onto the 3D structure. A tool interacting with the 3D structure is tracked and the interaction is analyzed. A visualization of the projected digital model is updated based on the analysis.