Digital Model Defect Mapping Using Sensor Correlation
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Solution Overview
Problem
Current methods for identifying and mapping defects on manufactured parts are imprecise and burdensome, as they rely on manual markings on paper drawings or estimated three-dimensional coordinates, which can be incomplete and inaccurate.
Innovation Solution
A computer-implemented method and apparatus that uses sensor data to correlate the position of physical points on a manufactured object to a digital model, calculating alignment probabilities and storing the aligned positions for precise defect mapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual marking on paper drawings is used to identify defect location, then the method is simple to operate, but the measurement precision and manufacturing precision are poor
Solution Approach 1:
The patent creates a digital copy (virtual model) of the physical manufactured object, allowing defect positions to be mapped precisely onto the digital representation. This digital twin approach enables accurate defect localization without requiring complex physical measurement devices, as the sensor data is correlated to the virtual model where precise positioning is achieved through coordinate transformation algorithms.
Solution Approach 2:
The patent replaces manual mechanical marking methods with an automated sensor-based system. Instead of physically marking paper drawings by hand, the system uses sensors to capture defect positions and automatically correlates them to the virtual model through computational algorithms, eliminating the imprecision of manual operations.
2Loss of information
If paper drawing marking is used for defect localization, then the ease of operation is maintained, but the loss of information occurs due to incomplete defect location data
Solution Approach 1:
By creating and utilizing a digital virtual model of the manufactured object, the system preserves complete defect location information in digital format. The virtual model retains all geometric and spatial data, allowing full defect position information to be stored and analyzed without the information loss inherent in manual paper marking methods.
Solution Approach 2:
The system automatically correlates sensor data to the virtual model and stores defect information without requiring manual intervention for data entry or marking. The automated process eliminates information loss by directly capturing and preserving complete defect location data through computational correlation rather than manual transcription.
3Reliability
If estimated three-dimensional coordinates are logged by user, then the ease of operation is maintained, but the measurement precision and reliability are poor
Solution Approach 1:
The patent replaces unreliable manual estimation of three-dimensional coordinates with an automated sensor-based measurement system. Sensors objectively capture defect positions, and computational algorithms automatically correlate these measurements to the virtual model, eliminating human estimation errors and significantly improving data reliability.
Solution Approach 2:
The system uses the virtual model as a reliable reference framework to which sensor measurements are correlated. This digital twin approach provides a consistent, accurate coordinate system that enhances the reliability of defect position data compared to manual estimation methods.
4Productivity
If manual defect location marking is used, then the device complexity is low, but the productivity is reduced due to burdensome user processes
Solution Approach 1:
The patent replaces manual defect mapping processes with an automated system that uses sensors to capture defect positions and computational algorithms to correlate them with the virtual model. This automation eliminates time-consuming manual marking and data entry, significantly improving defect mapping productivity despite the increased system complexity.
Solution Approach 2:
By utilizing the virtual model as a digital workspace, the system enables rapid defect location mapping without the physical constraints of paper drawings. The digital environment allows for efficient data storage, retrieval, and analysis, enhancing productivity in defect identification and tracking processes.
Data Source
AI summary
A computer implemented method, apparatus and computer usable program product for mapping a position of a physical point on a digital model. Sensor data for the physical point is received from a sensor unit and a position of the physical point is correlated to the digital model. An alignment probability for the correlated position is calculated and the calculated value is then compared to a stored threshold value. If the alignment probability for the correlated position does exceed a predetermined threshold probability, an aligned position is formed. An aligned position of the physical point is stored relative to the digital model, responsive to a store map location command.