Assembly Validation Path Planning for Automated Guided Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual validation of complex structure assembly, such as aircraft fuselage, is time-consuming, prone to errors, and requires specialized training, making it inefficient and inaccurate.
Innovation Solution
An automated validation method using a sensor system coupled with an automated guided vehicle to generate images of the structure, which are registered to a computer model, segmented, and scored to determine the condition of assembly, reducing human intervention and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection is performed by human operators comparing build to printed engineering drawings or CAD models, then validation can be performed with existing tools, but the process is time-consuming and more prone to error
Solution Approach 1:
The patent replaces manual mechanical inspection processes with an automated optical measurement system. A sensor system captures images of the structure, which are then processed through image registration and segmentation algorithms to automatically validate assembly conditions, eliminating human operators from the direct measurement process
Solution Approach 2:
The patent creates a digital copy of the physical structure by capturing images with a sensor system and registering them to a computer model. This digital replica enables automated analysis and validation without requiring physical manual measurement, significantly reducing time while maintaining or improving accuracy
2Measurement precision
If manual inspection requires operators to maneuver through hundreds of printed engineering drawings or CAD models, then detailed validation can be performed, but special training and experience are required
Solution Approach 1:
The system performs self-validation by automatically processing images through registration and segmentation algorithms that compare the captured structure against the computer model. The system validates assembly conditions without human intervention in the measurement process, eliminating the need for specialized operator training while maintaining detailed validation capability
Solution Approach 2:
The patent introduces image processing algorithms as an intermediary between the physical structure and the validation decision. These algorithms automatically segment images to identify features of interest and compare them against the computer model, serving as a mediator that eliminates the need for human operators to manually interpret hundreds of drawings
3Productivity
If automated validation uses a sensor system coupled to an automated guided vehicle to capture images and process them through registration and segmentation, then validation speed and accuracy improve, but system complexity increases
Solution Approach 1:
The patent employs a computer model that serves multiple functions: it stores design specifications, provides a reference for image registration, and enables automated validation against assembly conditions. This multi-functional approach consolidates what would otherwise require separate systems into a unified platform, managing complexity while maintaining high productivity
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method and apparatus for establishing a pathway for performing an automated validation of a condition of assembly. A sensor system coupled to an automated guided vehicle is moved into test positions relative to the structure. Image data is generated at each test position, using the sensor system, to build test images. Each test image is registered to a computer model of the structure to form registered images that are added to a collection of registered images. An optimal set of positions that will allow an entirety of an area of interest to be captured using a fewest number of registered images from the collection of registered images is determined. A pathway is generated for moving the automated guided vehicle to each optimal position in a least amount of time. A computer file identifying the pathway is generated for use in performing the automated validation of the condition of assembly.