Assembly Alignment Inspection via Derivative Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional assembly procedures, especially 'no-disassembly' methods, face challenges in ensuring quality due to increased production rates, leading to defects like contamination, burrs, and misalignment, which are difficult to inspect non-destructively, resulting in potential long-term quality issues and increased risks during ad-hoc testing.
Innovation Solution
A method and device for inspecting alignment between elements using double-access fastening means by measuring movement, assembly force, and torque parameters, calculating their derivatives, and analyzing these to detect alignment phases, allowing for real-time non-destructive quality assessment and reducing the likelihood of non-conformities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If no-disassembly procedures are used to increase production rates, then productivity is improved, but manufacturing precision deteriorates due to increased defects like contamination, burrs, and misalignment
Solution Approach 1:
The patent applies preliminary action by performing alignment inspection during the piercing phase before final assembly is completed. The system measures alignment parameters and generates reports that allow corrective actions to be taken before the assembly leaves the production line, thus maintaining high productivity while ensuring quality
Solution Approach 2:
The patent implements feedback by continuously monitoring alignment parameters during the assembly process and providing real-time information about alignment quality. This feedback loop enables immediate detection and correction of alignment issues without requiring disassembly or stopping production, resolving the contradiction between speed and precision
2Loss of time
If no-disassembly procedures are used to eliminate reference tasks, then loss of time is reduced, but reliability deteriorates due to inability to inspect and rectify defects
Solution Approach 1:
The patent replaces mechanical inspection methods (which require disassembly and visual examination) with an optical measurement system. The system uses cameras and image processing to automatically detect alignment defects during the piercing phase, eliminating the need for time-consuming manual inspection while maintaining or improving reliability
Solution Approach 2:
The patent introduces an intermediary alignment measurement system that bridges the gap between the piercing process and final quality assurance. This intermediary system provides continuous alignment monitoring and generates reports that enable quality verification without requiring disassembly, thus maintaining reliability while reducing inspection time
3Loss of time
If piercing is performed after sealant application during tack time, then loss of time is reduced, but object-affected harmful factors increase due to cutting fluid seepage at the interface
Solution Approach 1:
The patent applies preliminary action by performing alignment inspection during the piercing phase before sealant application interferes with quality. The system detects potential contamination issues and alignment defects early in the process, allowing corrective actions to be taken before the harmful effects of cutting fluid seepage occur
Solution Approach 2:
The patent implements feedback by monitoring alignment parameters during piercing and providing real-time alerts about potential contamination risks. This feedback enables operators to adjust the process or take corrective actions before cutting fluid seepage compromises the sealant interface, thus reducing harmful factors while maintaining fast assembly
Data Source
AI summary
A method for inspecting the quality of an alignment between the elements of an assembly, and an associated device, the method of which comprises tasks consisting of measuring a first parameter with a first measuring means, said first parameter being selected from a movement parameter of at least one part of the double-access fastening means, an assembly force parameter or a torque, measuring a second parameter with a second measuring means, said second parameter being selected from the same parameters and being different from the first parameter, calculating a value of a first derivative of a function representing a change in the second parameter relative to the first parameter by suitable information processing means, and analyzing the value of the first derivative to check the alignment between the elements to be assembled.