AR Work Instructions for Batch Operations Without Operator Stations
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Solution Overview
Problem
In batch manufacturing and continuous operations, operators often face challenges in accessing and confirming instructions without an operator station, leading to cycle time delays, quality issues, and safety hazards, especially in environments where traditional computing peripherals are cumbersome or impractical.
Innovation Solution
An augmented reality (AR) device with scope of responsibility awareness is used to display interactive messaging and instructions, allowing operators to view and confirm batch production or sequential operation data without an operator station, using a visual overlay that augments industrial equipment and supports both automated and manual tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional operator stations are used to display batch production data, then operators can access comprehensive information, but the physical footprint and cost of multiple operator stations increase
Solution Approach 1:
The patent uses AR devices to create a virtual copy of the operator station interface, displaying batch production data, procedural messages, and instructions directly in the operator's field of view. This eliminates the need for physical operator stations while maintaining full access to required information through augmented reality overlays
Solution Approach 2:
The patent transitions from two-dimensional physical displays to three-dimensional spatial displays by projecting batch production data into the operator's visual space. The AR interface renders information in multiple layers and dimensions, allowing operators to access comprehensive data without physical equipment
2Ease of operation
If operators leave the control room to work in the field, then they can perform hands-on tasks, but they may miss pending messages or instructions requiring confirmation
Solution Approach 1:
The AR device continuously monitors and displays pending messages and instructions in the operator's field of view, providing real-time feedback even when the operator is mobile. The system tracks message status and ensures confirmation requirements are visible and trackable throughout the field work environment
Solution Approach 2:
The AR device acts as an intermediary between the control system and the field operator, delivering messages and instructions directly to the operator's visual field regardless of location. This intermediary function ensures no messages are missed during field operations
3Manufacturing precision
If operators wear gowns and gloves in sterile environments, then they maintain clean room standards, but interacting with traditional computing peripherals becomes cumbersome
Solution Approach 1:
The patent replaces mechanical interaction with physical peripherals (keyboards, mice, touchscreens) with voice-based and gesture-based controls. Operators can issue commands and interact with the AR interface using voice instructions or simple hand gestures, eliminating the need for physical contact with computing devices while maintaining clean room standards
Solution Approach 2:
The AR system provides self-service capabilities where operators can access information, confirm messages, and interact with the system through natural voice commands or gestures without requiring traditional computing peripherals. The system adapts to the operator's constrained environment by providing hands-free operation modes
4Productivity
If operators delay confirmation of messages, then they can complete current tasks, but batch cycle time increases and quality may be impacted
Solution Approach 1:
The AR device provides continuous visual feedback about pending messages and their urgency level, allowing operators to prioritize confirmations appropriately. The system displays message age, urgency indicators, and impact information to help operators make informed decisions about confirmation timing without compromising batch quality or cycle time
Solution Approach 2:
The system prepares and pre-displays message information in the AR interface before operators need to confirm, organizing pending messages by urgency and relevance. This preliminary presentation allows operators to quickly assess and confirm messages without delays, maintaining both productivity and batch cycle time requirements
Data Source
AI summary
Methods and systems for the delivery of interactive messaging and instructions through an augmented reality device in a batch production or a sequential operation, can involve displaying a menu through a user interface associated with an augmented reality device configured with a scope of responsibility awareness that allows the augmented reality device to display a visualization of batch production data associated with a batch production or sequential operation data associated with a sequential operation that is within an assigned scope of responsibility of a user, and graphically expanding the menu in response to an input by the user. The expanded menu can include graphically displayed buttons that allow the user to select and view the batch production data or the sequential operation data. The visualization of the batch production data or the sequential operation data can be displayed without the need for an operator station.