Defect Detection Device Segmentation for Faster Data Transfer

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Solution Overview

Problem

Traditional methods for manual surface inspection in manufacturing environments, such as the steel industry, are inadequate for detecting defects, leading to increased operational costs and delays in decision-making due to the complex integration of surface defect data with production data, which hampers efficient data transfer and storage.

Innovation Solution

A method and system that utilize a defect detecting device to separate and prioritize the transfer of surface defect data over a secondary communication link with a faster data transfer rate, distinct from the primary communication link used for production data, allowing for efficient storage and faster run-time decision-making.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If surface defect data and production data are transferred through the same communication channel, then data integration is simplified, but data transfer speed decreases and decision-making is delayed

Engineering Contradiction:

Improvedata transfer system complexityVSAvoiddecision-making delay

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The patent segments the communication system into two separate communication channels: a first communication channel for transferring production data and a second communication channel for transferring surface defect data. This segmentation allows each channel to be optimized for its specific data type, with the second channel configured for faster transfer speeds to prioritize defect information delivery to the IT system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The defect detecting device acts as an intermediary that receives data from the manufacturing process, identifies surface defect data, and routes it through a dedicated faster communication channel to the IT system. This intermediary function separates the defect data transfer path from the general production data path, enabling prioritized handling of critical defect information.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If manual surface inspection methods are used, then operational costs are reduced, but defect detection quality and reliability decrease

Engineering Contradiction:

Improveoperational costVSAvoiddefect detection reliability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent replaces manual surface inspection methods with an automated defect detecting device that uses optical or sensing mechanisms to detect surface defects. This substitution eliminates the need for human operators to manually inspect surfaces, thereby reducing operational costs while simultaneously improving defect detection reliability through consistent, automated measurement and identification.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If surface defect data is transferred over the primary communication link, then system complexity is reduced, but data transfer speed and responsiveness decrease

Engineering Contradiction:

Improvecommunication system complexityVSAvoiddata transfer rate

Core Design Contradiction:

Device complexityVSSpeed

Solution Approach 1:

The communication system is segmented into two distinct channels: a first communication channel for production data and a second communication channel specifically for surface defect data. The second channel is configured with higher transfer rates to ensure rapid delivery of defect information, while the first channel handles general production data at standard speeds.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the transfer rate parameter of the communication channel by implementing a second communication channel with a faster data transfer rate than the first channel. This parameter change enables the system to prioritize and accelerate the transfer of critical surface defect data to the IT system without affecting the transfer of other production data.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10560369B2Methods and systems for detecting and transferring defect information during manufacturing processes

Publication Date: 2020.02.11 WIPRO LTD

AI summary

A method, corresponding system, and computer program product for detecting and transferring defect information during a manufacturing process is disclosed. The method includes receiving data to be transferred from a source to a destination over a primary communication link. The method identifies at least one type of data in the received data in response to receiving the data to be transferred over the primary communication link. Thereafter, the method allows transfer of a first type of data from the at least one type of data to the destination over a secondary communication link, the first type of data corresponding to the defect information, and wherein the secondary communication link is different from the primary communication link. Further, the method allows transfer of a second type of data from the at least one type of data to the destination over the primary communication link.