AR Visualization System for Industrial Automation Procedures
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Solution Overview
Problem
Operators in industrial automation environments face challenges in performing tasks efficiently due to the need to memorize device-specific procedures and identify changes in industrial automation devices, leading to potential errors and increased downtime.
Innovation Solution
An interactive augmented reality (AR) user experience (UX) system that provides visualizations of real-world and computer-generated content, guiding operators through maintenance and operation procedures by overlaying animated virtual objects onto real-time images of industrial automation devices, reducing the likelihood of errors and improving operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operators rely on memorization of device-specific procedures, then they can perform tasks without external aids, but error rates increase and training time increases
Solution Approach 1:
The patent introduces an augmented reality system as an intermediary between the operator and the industrial automation device. The AR system overlays procedural instructions, visual guides, and real-time feedback directly in the operator's field of view, serving as a cognitive aid that reduces reliance on memorization while decreasing errors and training requirements
Solution Approach 2:
The system implements real-time feedback mechanisms where the AR device monitors operator actions, compares them against correct procedures, and provides immediate corrective guidance. This closed-loop feedback reduces errors by preventing incorrect actions and accelerates learning by reinforcing correct procedures during actual task performance
2Adaptability or versatility
If operators must identify changes in industrial automation devices, then they can adapt to new configurations, but task completion time increases
Solution Approach 1:
The AR system continuously monitors the device state through integrated sensors and image recognition, automatically detecting configuration changes and updating the overlaid procedural guidance in real-time. This eliminates the need for operators to manually identify changes, maintaining adaptability while reducing task completion time
Solution Approach 2:
The system pre-loads and displays procedural instructions that anticipate required actions based on the current device state. When changes are detected, the AR system proactively updates the guidance before the operator needs to act, allowing seamless adaptation without increasing task completion time
3Manufacturing precision
If detailed procedural instructions are provided to operators, then task accuracy improves, but information overload occurs and ease of operation decreases
Solution Approach 1:
The AR system applies the principle of local quality by providing context-specific information only at the relevant moment and location. Procedural instructions are overlaid directly on or near the specific component being manipulated, and details are revealed progressively as the operator progresses through the task, maintaining accuracy without causing information overload
Solution Approach 2:
The procedural information is segmented into discrete, manageable steps that are presented sequentially. Each AR overlay contains only the immediate next action required, breaking down complex procedures into small cognitive chunks that are easy to process while maintaining overall task accuracy
Data Source
AI summary
A system may include a processor and a memory. The memory may include computer-executable code that, when executed by the processor, causes the processor to retrieve a workflow dataset from a database based on a query input associated with an industrial automation device. The workflow dataset may include an instruction associated with one or more operations for the industrial automation device and a virtual object associated with the one or more instructions and the industrial automation device. The memory may include computer-executable code that, when executed by the processor, causes the processor to transmit a first portion of the workflow dataset to a computing device corresponding to a first instruction. The memory may include computer-executable code that, when executed by the processor, causes the processor to transmit a second portion of the workflow dataset to the computing device in response to determining that the first instruction is completed.