Industrial Process Monitoring for Real-Time Thermal Defect Classification
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Solution Overview
Problem
Existing industrial processes face challenges in timely identification of deviations in equipment and item properties due to slow data processing rates, leading to manufacturing defects and inefficiencies.
Innovation Solution
A method and system for real-time data processing of industrial processes using computing hardware to analyze media elements, extract attribute values, construct data structures, and generate graphical representations to detect deviations and adjust processing parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If still image surveillance equipment is used to monitor industrial processes, then large problems in individual items can be detected, but variations over time in items and gradual variations in manufacturing processes cannot be revealed
Solution Approach 1:
The patent segments the continuous manufacturing process into discrete time intervals by capturing images at multiple timestamps. Each timestamp represents a segment of the process, allowing comparison of variations over time. The system divides the temporal dimension into manageable units that can be analyzed individually and collectively to detect gradual changes.
Solution Approach 2:
The system performs preliminary action by capturing and storing images at multiple timestamps before final analysis. This preliminary data collection at different time points enables subsequent comparison and detection of variations that would be invisible in single snapshot images.
2Productivity
If closed-circuit television systems are used for real-time surveillance, then equipment malfunctioning can be detected, but gradual variations over time and minor variations in rapid processes are missed due to slow frame rates
Solution Approach 1:
The patent applies dynamics by adjusting the frame rate of image capture based on the specific process being monitored. For rapid processes, the system increases frame rate to capture minor variations, while for slower processes, it uses lower frame rates. This dynamic adjustment optimizes both monitoring speed and detection accuracy for different manufacturing scenarios.
Solution Approach 2:
The system changes the parameter of frame rate according to the monitoring requirements. By varying this temporal parameter, the system can resolve rapid processes with high precision while maintaining efficient monitoring speed, overcoming the limitation of fixed frame rate CCTV systems.
3Measurement precision
If control systems operate at slow rates to measure properties of equipment components, then comprehensive measurements can be taken, but timely correction of processing parameters cannot be achieved, leading to manufacturing of defective items
Solution Approach 1:
The system performs preliminary measurement and analysis at multiple timestamps, building a comprehensive understanding of process variations before making control adjustments. This preliminary action at different time points enables both complete measurement and timely response by preparing the data foundation in advance.
Solution Approach 2:
The patent implements feedback by continuously comparing images from multiple timestamps and using this comparison to adjust processing parameters in real-time. The feedback loop operates at high speed by leveraging the temporal information already captured, enabling timely correction while maintaining measurement precision.
Data Source
AI summary
Aspects of the present invention provide methods, systems, and/or the like for: (1) determining temperature data for at least part of an article of manufacture in a manufacturing process; (2) analyzing the temperature data to identify a first portion of the article of manufacture having a temperature that deviates from a surrounding portion of the first portion, the first portion comprising: at least one hot spot, at least one hot streak, at least one cold spot, or at least one cold streak on the article of manufacture; (3) determining, for the first portion of the article of manufacture, a set of properties related to the temperature: (4) processing the set of properties using at least one of a rules-based model, a machine-learning model, or a classification model to produce a defect classification; and (5) providing an indication of the defect classification for display on a computing device.