Assembly Validation Using Wearable AR for Torque Monitoring
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Solution Overview
Problem
In manufacturing settings, there is a lack of effective methods to validate proper installation and removal of machine components during assembly or disassembly processes, often resulting in improper fastening or unfastening, which can lead to thread damage, slippage, or machine part failure.
Innovation Solution
A method utilizing wearable devices, IoT devices, and augmented reality to monitor and guide users through the assembly or disassembly process, providing real-time feedback on torque, alignment, and force application, and alerting users to potential issues such as thread damage or faulty parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembly methods without validation are used, then the assembly process is simple and fast, but improper fastening can lead to thread damage, slippage, or machine part failure
Solution Approach 1:
The patent implements feedback mechanisms through wearable devices that monitor torque application, force distribution, and assembly steps in real-time. Sensors detect whether bolts are properly torqued, whether excessive force is applied during insertion, and provide immediate feedback to guide the assembler to correct improper actions before damage occurs.
Solution Approach 2:
The patent replaces manual mechanical assembly validation with electronic sensing and computational analysis. Instead of relying on assembler skill and traditional mechanical checkers, the system uses force sensors, torque sensors, and computer vision to automatically detect and validate assembly correctness.
2Measurement precision
If manual assembly without monitoring is used, then the operation is straightforward, but it is difficult to detect and measure improper fastening or thread damage
Solution Approach 1:
The patent uses electronic sensors and computer vision systems to replace manual inspection. Force sensors measure insertion forces to detect cross-threading, torque sensors verify proper bolt tightening, and cameras with image processing identify visual defects that would be difficult for human operators to detect consistently.
Solution Approach 2:
The patent introduces intermediary sensing devices between the assembler and the machine components. Wearable devices with sensors act as intermediaries that measure forces, torques, and positions, translating physical assembly actions into digital data that can be analyzed to detect improper fastening and thread damage.
3Manufacturing precision
If real-time monitoring and validation are implemented, then assembly accuracy and safety are enhanced, but the assembly process becomes more complex and requires additional devices
Solution Approach 1:
The patent implements self-service validation where the system automatically monitors, analyzes, and validates assembly actions without requiring separate inspection steps. The wearable devices and sensors continuously self-monitor assembly parameters and provide real-time guidance, eliminating the need for additional manual validation operations.
Solution Approach 2:
The patent creates a multi-functional integrated system where wearable devices serve multiple purposes: guiding assembly steps, monitoring forces and torques, detecting improper actions, providing real-time feedback, and recording assembly data. This consolidation reduces the need for multiple separate monitoring devices.
Data Source
AI summary
A method for validating proper installation and removal of machine components during an assembly or a disassembly process includes identifying a current step in an assembly or disassembly process. The method further includes displaying appropriate positioning and alignment for at least one individual part and at least one tool for the current step in the assembly or the disassembly process. The method further includes monitoring a plurality of actions of a user while performing the current step in the assembly or the disassembly process. The method further includes, responsive to determining a corrective action is required for the current step, determining a recommendation based on the corrective action, the at least one individual part, and the at least one tool. The method further includes displaying the recommendation in an augmented device associated with the user.