Clear-Body Defect Detection Tool for Objective Garment Inspection
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Solution Overview
Problem
The clothing and fashion industry faces challenges in inspecting inbound articles for defects due to lack of objective and repeatable inspection standards, leading to inaccurate tracking and poor customer experience, especially when items require frequent inspection for quality.
Innovation Solution
A method and system using a defect detection tool with a clear body and surface elements, such as linear or circular features, to objectively inspect articles for physical defects, updating an article tracking system based on the inspection results, ensuring consistent and accurate reporting across multiple inspection areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If customer-based defect reporting is used, then operational cost is reduced, but measurement precision and reliability of defect detection deteriorate
Solution Approach 1:
The inspection tool enables the inspection process to be self-sufficient by providing built-in objective standards (surface elements) that automatically guide defect detection without requiring external reference materials or expert judgment, allowing consistent inspection while maintaining operational efficiency
Solution Approach 2:
The patent transforms the abstract concept of defect size into a measurable parameter by providing physical surface elements with defined dimensions (e.g., 1mm, 2mm, 5mm circles and lines), enabling quantifiable defect assessment that improves measurement precision while maintaining ease of use
2Manufacturing precision
If detailed inspection of multiple article categories is performed, then manufacturing precision of inspection standards is improved, but device complexity increases
Solution Approach 1:
The inspection tool is designed with multiple surface elements (different shapes, sizes, and patterns) that can universally apply to various article categories and defect types, allowing a single tool to perform multiple inspection functions without requiring separate tools for each article type
Solution Approach 2:
The tool body is segmented into multiple functional zones with different surface elements arranged in specific patterns, allowing inspectors to evaluate different defect characteristics (size, shape, distribution) simultaneously across various article categories without increasing overall device complexity
3Ease of operation
If manual defect inspection is performed, then ease of operation is maintained, but productivity decreases
Solution Approach 1:
The surface elements are pre-configured with standard defect size representations and arranged in optimal patterns on the tool body, allowing inspectors to quickly assess defects without performing preliminary measurements or calculations, thereby maintaining ease of operation while increasing inspection speed
Solution Approach 2:
The patent replaces complex measurement instruments and mechanical gauges with simple visual comparison against surface elements, eliminating the need for precise mechanical measurements while maintaining ease of operation and significantly improving inspection productivity through rapid visual assessment
4Measurement precision
If objective inspection standards are implemented, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The surface elements are designed with distinct visual characteristics (different colors, patterns, and shapes) that provide immediate visual feedback for defect size comparison, making objective measurement standards easily distinguishable and simple to apply without requiring complex interpretation or additional training
Data Source
AI summary
A method of inspecting an article with a defect detection tool includes receiving one or more articles at an inspection station and inspecting one of the received one or more articles at the inspection station by evaluating the article for at least one physical defect with the defect detection tool. The defect detection tool includes a clear body including a surface element sized to correspond to the at least one physical defect in the article, the surface element including at least one of a linear element or a circular element and an inspection surface configured to contact a surface of the article when the clear body is applied to the article. Evaluating the article for at least one physical defect with the defect detection tool includes applying the defect detection tool against the article to align the surface element with a potential physical defect in the surface of the article and determining that the at least one physical defect is present when the potential physical defect has a size equal to or larger than a size of the linear element or a size of the circular element.