Assembly Condition Validation Using Image-to-Model Registration
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Solution Overview
Problem
Current methods for validating the condition of assembly in complex structures, such as aircraft fuselages, are manual, time-consuming, and prone to errors, requiring significant human intervention and special training.
Innovation Solution
An automated validation system using a sensor system and automated guided vehicle to generate images of the structure, register them to a computer model, segment the images, and generate a score based on compliance with design specifications, reducing the need for human intervention and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection methods are used to validate assembly conditions, then human operators can perform the validation with special training, but the process becomes time-consuming and more prone to error
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical measurement system. A sensor system captures images of the structure, which are then processed by a validator to automatically compare actual assembly conditions against design specifications, eliminating human operators from the direct measurement process while improving both speed and accuracy
Solution Approach 2:
The patent creates a digital copy of the design specifications in the form of a computer model, and a digital copy of the actual assembly in the form of captured images. The validator then compares these digital copies to determine compliance, replacing physical manual measurement with digital analysis
2Ease of operation
If manual inspection of complex structures is performed, then operators can evaluate assembly conditions, but special training and experience are required to maneuver through drawings or models
Solution Approach 1:
The patent replaces the need for trained human operators navigating complex drawings with an automated system. The validator computer automatically processes captured images, registers them to the computer model, and compares features against design specifications, making the operation simple while maintaining high reliability through automated consistent evaluation
Solution Approach 2:
The system performs self-validation by automatically capturing images, processing them through the validator, and generating compliance determinations without human intervention. The automated guided vehicle also navigates autonomously through the structure to capture images from required positions
3Reliability
If comprehensive validation of assembly conditions is performed, then quality control is ensured, but the process requires significant human intervention and resources
Solution Approach 1:
The patent segments the validation process into distinct automated components: an automated guided vehicle for navigation, a sensor system for image capture, a validator for processing, and a registration system for alignment. This segmentation distributes the complexity across specialized subsystems while maintaining overall system automation and reducing human intervention requirements
Solution Approach 2:
The patent introduces a computer model as an intermediary between the physical structure and the validation process. The validator compares captured images against this digital model, which serves as a mediator that translates design specifications into machine-readable format, enabling automated quality control without direct human analysis of complex drawings
4Measurement precision
If multiple images are captured for comprehensive validation, then complete coverage of the structure is achieved, but the number of images and processing resources required increases
Solution Approach 1:
The patent implements selective image capture by the automated guided vehicle, which navigates to specific positions and orientations that provide the most valuable validation data. The system captures enough images to achieve complete validation coverage of critical features while avoiding redundant captures, optimizing the balance between measurement precision and quantity of images processed
Data Source
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AI summary
A method and apparatus for performing an automated validation of a condition of assembly for a structure. A plurality of images of the structure are registered to a computer model of the structure in which an image in the plurality of images captures a portion of the structure. Each image in the plurality of images is segmented based on registration of the plurality of images to the computer model to form a plurality of image sections. A final score is generated for the condition of assembly of the structure based on whether each image section in the plurality of image sections meets a corresponding condition in which the final score indicates whether the condition of assembly is valid.