Visual Inspection Jig Alignment for Multi-Connector Assemblies
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Solution Overview
Problem
Inspecting highly integrated complex assemblies efficiently while reducing consumer and producer risks is challenging, particularly in manufacturing applications where traditional methods are inefficient and prone to errors.
Innovation Solution
The implementation of a jig structure within a visual inspection system that allows for controlled movement along six degrees of freedom, combined with the use of artificial intelligence (AI) and machine learning (ML) for image analysis, enables efficient and repeatable imaging of complex assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional inspection methods are used for highly integrated complex assemblies, then the inspection process is simple, but the inspection efficiency is low and error-prone
Solution Approach 1:
The patent replaces traditional mechanical inspection methods with an automated imaging system that uses cameras, lighting, and computer vision technology. The jig structure mechanically positions components for imaging, but the actual inspection is performed optically and computationally, dramatically improving efficiency while reducing human error
Solution Approach 2:
The inspection system is designed to be self-contained with integrated lighting, imaging, and positioning capabilities. The jig structure automatically positions components in the imaging path, and the system performs its own inspection without requiring external intervention or complex manual setup procedures
2Adaptability or versatility
If a fixed imaging position is used, then the imaging setup is simple, but the system cannot accommodate multiple connector types or controlled movement
Solution Approach 1:
The jig structure incorporates movable components including sliding rails that allow linear movement, and reversible mount arrangements that enable connectors to be positioned in different orientations. This dynamic capability allows the same jig to accommodate multiple connector types and imaging configurations without requiring multiple dedicated fixtures
Solution Approach 2:
The jig structure is designed as a universal platform that can accommodate different connector types through its reversible mount arrangements and sliding components. The same basic structure serves multiple functions: positioning, orienting, and securing various connector types for imaging, eliminating the need for multiple specialized fixtures
3Ease of operation
If connectors are permanently fixed in the jig, then the positioning is stable, but the connectors cannot be easily removed or repositioned
Solution Approach 1:
The reversible mount arrangement provides a dynamic mounting system that transitions between secured and released states. When secured, the connector is firmly held for stable imaging; when released, the connector can be easily removed or repositioned. This dynamic characteristic resolves the contradiction between stability during operation and ease of manipulation
4Loss of time
If manual inspection processes are used, then the equipment complexity is low, but the cycle time is approximately 30 minutes per assembly
Solution Approach 1:
The system replaces manual inspection with automated imaging and computer vision analysis. Multiple cameras capture images simultaneously, and software automatically processes and analyzes the images to identify defects or verify assembly correctness, reducing inspection time from 30 minutes to a fraction of that time
Solution Approach 2:
The system combines multiple imaging functions into a single integrated platform. Multiple cameras, lighting sources, and positioning mechanisms are merged into one coordinated system that performs comprehensive inspection in a single operation, dramatically improving throughput compared to sequential manual inspection steps
Data Source
AI summary
An imaging device is provided that may be used for visually inspecting structures. In one embodiment, the imaging device includes an image capture device; and a rail system having a stationary component connected to the image capture device and a sliding component for movement along a horizontal axis. The system can further include a jig structure engaged to the sliding component of the rail system. The jig structure may include a first mount location for engagement to a first type connector and a second mount location for engagement to a second type connector. The jig structure is engaged to the sliding component to position the housing so that the first and second mount locations are in line and parallel to a direction of travel along the horizontal axis including a point at which the first and second mount locations pass through the imaging location.