Color Harmonization Algorithm for Manufacturing Tolerances
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Solution Overview
Problem
Current methods for color harmonization in manufacturing, such as Poland's patent, fail to account for visual examinations and do not adjust manufacturing parameters based on visual acceptance, leading to labor-intensive processes, delays, and unsatisfied customers due to color inconsistencies.
Innovation Solution
A method that establishes numerical-visual color tolerances using algorithms and visual examination by a person or machine, allowing for the adjustment of manufacturing parameters to ensure visual acceptance, incorporating a 'color-part number' system, approved manufacturing routes, and iterative learning with AI to manage color variations and process variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional color measurement devices (spectrophotometer, colorimeter) are used to monitor part color, then color measurement can be performed at production points, but disparate measurements occur due to texture variations and base substrate not being controlled
Solution Approach 1:
The patent introduces a standardized substrate as an intermediary between the measurement device and the part being measured. This substrate provides a controlled, uniform background that eliminates variations caused by different base materials and textures, allowing consistent color measurements across different parts and production points.
Solution Approach 2:
The patent changes the measurement parameters by controlling lighting conditions, measurement angles, and substrate properties. By standardizing these parameters, the system achieves consistent color measurements that accurately reflect true color variations rather than measurement artifacts.
2Reliability
If multiple color tests and empirical processes are used to obtain color specification acceptance, then color approval can be achieved, but labor and machinery costs increase, delivery times are delayed, and multiple tuning operations are required
Solution Approach 1:
The patent performs color measurements and adjustments during the manufacturing process itself, rather than waiting for final assembly and multiple testing rounds. By measuring and adjusting colors preliminarily at the part level, the system prevents color issues from propagating to final assembly, eliminating the need for repeated tuning operations.
Solution Approach 2:
The patent implements a feedback loop where color measurements are continuously monitored during production, and adjustments are automatically made based on measured deviations. This real-time feedback system ensures color specification acceptance while minimizing the number of testing iterations required.
3Loss of information
If new part numbers are generated for each different part and color combination, then color specifications can be tracked, but the process becomes labor-intensive and requires exhaustive interdepartmental organizational effort
Solution Approach 1:
The patent creates a universal color measurement and management system that can handle multiple parts, colors, and specifications through a single integrated platform. This system uses standardized measurement procedures and a centralized database that automatically tracks all color specifications, eliminating the need for separate processes for each part-number/color combination.
4Manufacturing precision
If predefined color parameters are used in existing systems, then color consistency can be monitored, but parts accepted after visual examination may be rejected by the system since visual acceptance does not always align with predefined parameters
Solution Approach 1:
The patent makes the color parameter specifications dynamic rather than static. The system continuously learns from visual examination results and automatically adjusts the predefined parameters to reflect actual customer acceptance criteria. This dynamic adaptation ensures that the system's parameter control aligns with real-world visual acceptance over time.
Data Source
AI summary
The invention relates to a method for the harmonization of color in manufactured items, which allows color tolerances to be established based on pre-defined values and visual observations for the different parts that form the item and the operating conditions for the manufacture of said parts by which means the colors falling within said tolerances can be obtained as well as the acceptance of the color harmonization of the final product by means of the use of algorithms and visual examination by a person or a machine.