Automated Joint Inspection via Surface Geometry Scanning
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Solution Overview
Problem
High volume mechanical jointing operations face inefficiencies in inspecting the quality of formed joints, relying on subjective human inspection and lacking real-time feedback for quality control, which can lead to substandard or defective joints.
Innovation Solution
An automated system comprising a sensor and a controller that scans the workpiece to generate data on surface geometry, identifying geometric features of mechanical joints, such as height and location, and adjusts the automated device to form subsequent joints based on predetermined specifications, enabling objective and real-time inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated high volume jointing operations are implemented, then productivity increases, but the ability to inspect joint quality in real-time deteriorates when relying on manual inspection methods
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical sensing system that uses sensors to detect geometric features of mechanical joints. The sensor system captures images or data about joint geometry, and a controller automatically analyzes this data to determine joint quality, eliminating the need for manual inspection while maintaining inspection reliability in high-volume operations.
Solution Approach 2:
The patent implements a feedback mechanism where the sensor system continuously monitors joint quality and provides real-time information to the controller. This feedback loop enables immediate detection of defective joints and allows for real-time adjustments to the jointing process, ensuring consistent quality in automated high-volume operations.
2Adaptability or versatility
If manual inspection of mechanical joints is performed, then flexibility in handling various joint types is maintained, but inspection precision and objectivity deteriorate
Solution Approach 1:
The patent uses a sensor system that can detect multiple geometric parameters of mechanical joints, such as head height, head diameter, joint position, and joint geometry. By measuring these specific parameters objectively, the system achieves high precision in joint quality assessment while maintaining adaptability through programmable inspection criteria that can be adjusted for different joint types.
3Loss of time
If random sampling inspection is used in high volume jointing, then inspection time is reduced, but the ability to detect defects deteriorates
Solution Approach 1:
The patent implements continuous inspection where the sensor system scans every mechanical joint as it is formed, rather than inspecting random samples. The sensor continuously captures data about joint geometry, and the controller continuously analyzes this data to identify defective joints, ensuring no defects are missed while maintaining high production speed through automated real-time inspection.
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
This system allows for immediate identification and correction of substandard joints, reducing defects and improving overall joint quality through automated, in-process inspection, enhancing the efficiency and reliability of high volume jointing operations.
Implementation Method 1
A sensor is coupled to the automated device in order to scan the workpiece and generate data indicating the surface geometry of the workpiece
Data Source
Figure 1A~2B
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AI summary
A method of sequentially performing a plurality of jointing operations includes positioning an automated device to form a mechanical joint into a workpiece and forming a mechanical joint into the workpiece. Once the mechanical joint is formed, the workpiece is scanned to generate data indicating the surface geometry of the workpiece at a location including the mechanical joint. One or more geometric features of the surface geometry are identified, and if the identified geometric features are within respective predetermined specification thresholds, the automated device is repositioned to form a subsequent mechanical joint into the workpiece.