Digital Twin Simulation for Assembly Defect Detection
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Solution Overview
Problem
The manufacturing process of composite products often results in defects due to lack of compatibility and tolerance verification of components before assembly, leading to additional costs and supply chain delays as defects are noticed only during assembly.
Innovation Solution
A computer-implemented method that generates a digital representation of component batches and creates a digital twin simulation to identify potential defects in a virtual environment, allowing for alerts and recommendations to prevent assembly issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If component batches from disparate providers are assembled without prior compatibility verification, then manufacturing speed and productivity are improved, but assembly defects increase leading to redesign costs and supply chain delays
Solution Approach 1:
The patent performs compatibility and tolerance verification of components from disparate providers in advance of actual assembly through digital twin simulation. By creating virtual representations of component batches and simulating their assembly beforehand, the system identifies potential defects before physical assembly occurs, enabling proactive resolution of compatibility issues while maintaining high assembly productivity.
2Measurement precision
If digital twin simulation is implemented to verify component compatibility before assembly, then assembly defect detection is improved, but computational resources and processing time increase
Solution Approach 1:
The patent creates digital twins - virtual copies or representations - of physical component batches to perform compatibility verification and defect detection in the virtual domain. By working with digital replicas instead of physical components, the system achieves high measurement precision for defect detection while avoiding the time-consuming nature of physical prototyping and testing, thus reducing overall processing time.
3Manufacturing precision
If representative samples are generated for each component batch in the virtual environment, then component variability analysis is improved, but data processing complexity increases
Solution Approach 1:
The patent generates representative samples from each component batch rather than processing every individual component. This partial action approach focuses computational resources on creating a manageable set of representative digital twins that capture the essential variability and tolerance characteristics of each batch, achieving sufficient manufacturing precision for tolerance verification without overwhelming data processing complexity.
Data Source
AI summary
A computer-implemented method, system and computer program product for optimizing a manufacturing process of a physical product using a virtual environment. A representative sample as a digital representation for each batch of components to be assembled into the physical product is generated based on component batch data. A digital twin simulation in a virtual environment using the digital representation for each batch of components is then created and executed to determine potential defects in assembling components into the physical product prior to actually assembling the components into the physical product. An analysis is performed in the simulation to determine whether any combination of components to be assembled into the physical product has been identified as failing to meet a predetermined tolerance range thereby identifying a potential defect in assembling the physical product. Upon identifying a potential defect, an alert is generated indicating a potential defect in assembling the physical product.