Assembly Process Inspection Using Sensor-Based Stage Recognition
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Solution Overview
Problem
Manual inspection of complex assembly processes, such as aircraft assembly, is prone to human error, is time-consuming, and costly, and requires extensive disassembly to identify issues, which is inefficient and costly.
Innovation Solution
An automated supervision and inspection system using sensor data, machine learning, deep learning, computer vision, and artificial intelligence to identify the current stage of assembly, assess quality, and generate reports, reducing the need for human intervention and enabling efficient identification of issue root causes without extensive disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used to identify assembly issues, then human operators can detect defects, but the inspection is prone to human error and less accurate
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses cameras and image processing algorithms to detect assembly defects. The system captures images of the assembly process and uses computer vision techniques to automatically identify missing parts, incorrect orientations, and assembly errors, eliminating human error and improving inspection accuracy and consistency.
2Measurement precision
If manual inspection is performed to identify assembly defects, then defects can be detected, but the process takes longer than desired
Solution Approach 1:
The patent implements continuous automated inspection throughout the assembly process rather than periodic manual checks. The optical inspection system operates continuously, capturing images at multiple stages of assembly and immediately processing them to identify defects, thereby reducing total inspection time while maintaining comprehensive defect detection coverage.
Solution Approach 2:
The system performs preliminary automated inspection at each assembly stage before proceeding to the next stage, allowing defects to be identified and corrected early in the process. This prevents the accumulation of errors and reduces the need for time-consuming rework later in the assembly process.
3Measurement precision
If manual inspection is used to identify assembly issues, then defects can be found, but disassembly is required which is more time-consuming and costly
Solution Approach 1:
The automated optical inspection system performs preliminary detection of assembly defects at the exact stage where they occur, providing real-time feedback to operators. This allows issues to be corrected immediately during assembly rather than requiring disassembly later to identify the problem, thereby eliminating time-consuming disassembly operations and reducing overall manufacturing time and cost.
Data Source
AI summary
A method and apparatus for performing automated supervision and inspection of an assembly process. The method is implemented using a computer system. Sensor data is generated at an assembly site using a sensor system positioned relative to the assembly site. A current stage of an assembly process for building an assembly at the assembly site is identified using the sensor data. A context for the current stage is identified. A quality report for the assembly is generated based on the sensor data and the context for the current stage.