Digital Twin Assembly Guidance for Real-Time Deviation Correction
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Solution Overview
Problem
In assembly processes, not all relevant parameters are typically made available, leading to potential assembly issues that can be missed during the manufacturing of parts, which can result in suboptimal or incorrect assembly.
Innovation Solution
A computer-implemented method and system that receives digital twin instance part assembly information from sensor scans and compares it with digital twin framework part assembly data, using context data to determine deviations and provide corrective information to assemblers for re-assembly, ensuring alignment with predefined thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional assembly processes are used without comprehensive parameter monitoring, then the assembly process is simpler and faster, but assembly quality and detection of potential issues deteriorate
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the physical part assembly that mirrors the physical assembly process. Sensors scan the physical parts and update the digital twin in real-time, allowing virtual monitoring and comparison without adding physical monitoring complexity to the actual assembly process. The digital twin serves as a virtual replica that captures all assembly parameters and deviations.
Solution Approach 2:
The patent replaces physical monitoring devices and manual inspection methods with sensor-based scanning and digital modeling. Instead of using complex mechanical measurement tools during assembly, the system uses sensors to capture geometric data and a digital twin to process and analyze the information, substituting mechanical systems with optical and computational systems.
2Reliability
If real-time monitoring and comparison of assembly parameters are implemented, then assembly quality and error detection improve, but the time and computational resources required increase
Solution Approach 1:
The patent pre-establishes the digital twin framework and defines all relevant assembly parameters and tolerance thresholds before the actual assembly process begins. The framework part assembly data (FPAD) is prepared in advance, containing all expected geometric parameters and tolerance ranges. This preliminary setup enables rapid real-time comparison during assembly without requiring complex computations on the fly.
Solution Approach 2:
The patent implements continuous feedback by comparing instance part assembly data (IPAD) from sensor scans against the pre-defined framework data (FPAD) in real-time. When deviations are detected, the system immediately provides feedback to the assembler through the interface, allowing for immediate correction. This closed-loop feedback system ensures high reliability while maintaining efficient processing through automated real-time comparison.
3Loss of information
If comprehensive sensor scanning and digital twin modeling are used, then all assembly parameters become available for monitoring, but the system complexity and data processing requirements increase
Solution Approach 1:
The patent extracts only the relevant assembly parameters from the comprehensive sensor scan data that are necessary for quality control and comparison with the framework. Instead of processing all possible sensor data, the system identifies and extracts specific geometric parameters defined in the framework part assembly data (FPAD), such as positions, orientations, and dimensions of critical features. This selective extraction reduces data processing complexity while maintaining complete monitoring of essential assembly parameters.
Data Source
AI summary
A computer-implemented system and method for searching comprises receiving digital twin instance part assembly information (IPAD) from a sensor scan of a physical part assembly produced by assembling a first physical part with a second physical part. Digital twin framework part assembly data (FPAD) is received representing a correctly assembled physical part assembly and that corresponds to the physical part assembly. Context data associated with a context within which the physical part assembly is produced is also received. The FPAD is compared with the IPAD, utilizing the context data, to determine whether a deviation of the IPAD from the FPAD exceeds a threshold. Responsive to the deviation exceeding a threshold, the method comprises providing corrective information to a device of an assembler for re-assembling the first physical part to the second physical part to produce a reassembled physical part assembly based on the corrective information.