Hand Tool Position Tracking for Precise Assembly Operations
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Solution Overview
Problem
Existing systems for controlling manual operations during assembly of parts using a hand tool are expensive, prone to inaccuracies due to signal interference, and require complex beacon placement, failing to achieve the required precision and traceability of tightening operations.
Innovation Solution
A system using a portable hand tool equipped with a depth camera and inertial measurement unit, integrated with a processing module, aligns point clouds from captured images with CAD files to determine precise locations and movements, enabling real-time control and validation of manual operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If radiofrequency beacons are used for locating the hand tool, then the system can track tightening operations, but the system becomes expensive and signal accuracy deteriorates due to interference from metal structures
Solution Approach 1:
The patent replaces the radiofrequency-based locating system with a vision-based system using a depth camera. The camera captures images of the assembly, and image processing algorithms determine the hand tool's position and the tightening element's location based on visual features rather than radiofrequency signals, thereby avoiding interference from metal structures.
Solution Approach 2:
The patent creates a digital representation of the assembly by processing images from the depth camera. This visual model serves as a copy of the physical assembly, allowing the system to track and locate tightening elements through image recognition rather than direct radiofrequency measurement, improving precision in metallic environments.
2Reliability
If multiple radiofrequency beacons are deployed to improve location accuracy, then tracking coverage is enhanced, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the locating function from the hand tool itself and places it in the stationary assembly structure through the depth camera system. Instead of equipping the moving tool with multiple beacons, the system uses a fixed camera to capture images and determine positions, thereby reducing overall system complexity while maintaining tracking coverage.
Solution Approach 2:
The patent creates a digital model of the assembly structure that serves as a reference for locating tightening elements. This visual copy allows the system to track operations across the entire assembly without requiring multiple physical beacons, reducing device complexity while maintaining comprehensive coverage.
3Productivity
If radiofrequency signals are used for real-time control, then operational feedback is provided, but signal accuracy deteriorates due to reflection and interference from assembly structures
Solution Approach 1:
The patent substitutes radiofrequency signal-based control with vision-based control using a depth camera. The camera captures real-time images of the assembly, and processing algorithms provide feedback on hand tool position and tightening element status, maintaining real-time control capability while eliminating signal reflection and interference issues inherent in radiofrequency systems.
4Loss of information
If the locating system uses wave-based techniques, then remote monitoring is enabled, but the system fails to achieve millimeter-level precision required for some applications
Solution Approach 1:
The patent replaces wave-based locating techniques with direct visual measurement using a depth camera. The camera captures high-resolution images and uses image processing to determine the hand tool's position with millimeter-level precision, maintaining remote monitoring capability while achieving the required measurement accuracy that wave-based methods cannot provide.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides high-precision, cost-effective control of manual operations with real-time validation and traceability, ensuring accurate application of setpoint parameters and quality assurance of assembly processes.
Implementation Method 1
a depth camera belonging to said electronic module and a processing module able to estimate and save a current position of said portable hand tool
Implementation Method 2
portable hand tool equipped with a depth camera and inertial measurement unit
Data Source
AI summary
A system for controlling operations during production of an assembly of parts is provided. The system includes a tool for performing manual operations on a plurality of elements of the assembly of parts, and locating means integrated at least in part into an electronic module attached to the tool and able to determine a location of at least one operation associated with an element by locating the position of the tool in a three-dimensional coordinate system associated with a set of modelling data representing a three-dimensional modelled image of the assembly of parts. The locating means includes a depth camera belonging to the electronic module and a processing module able to estimate the position of the portable hand tool on the basis of images captured by the depth camera.