Junction Trace Mapping for Variable-Material Assembly Inspection
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Solution Overview
Problem
In industries like footwear manufacturing, where flexible materials and complex processing conditions prevail, establishing an accurate junction trace for assembly is challenging due to variations in part sizes and material properties, hindering the introduction of automation.
Innovation Solution
A system comprising a surface model creating module, a processing module, and a material inspection module that scans and analyzes parts to determine a junction region and inspection points, using multi-depth-of-field image capturing devices and nondestructive material inspection tools to establish a correct junction trace based on material inspection results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automation equipment is introduced to replace manpower in processing, then productivity is improved, but manufacturing precision deteriorates due to variations in part sizes and material properties
Solution Approach 1:
The system performs preliminary scanning and surface model creation of parts before processing. By capturing the actual geometry and material properties of each part in advance, the system establishes accurate junction traces that account for size variations and material characteristics, enabling automation equipment to process with high precision
Solution Approach 2:
The system changes the parameters used for junction trace establishment from fixed predetermined values to dynamic values based on actual part measurements. By scanning parts and analyzing their specific geometry and material properties, the system adapts processing parameters to each part's characteristics, maintaining manufacturing precision across variations
2Ease of manufacture
If predetermined junction traces are used for assembly processing, then ease of manufacture is improved, but reliability deteriorates due to inability to reflect actual assembly state
Solution Approach 1:
The system replaces manual visual inspection and manual trace drawing with automated optical scanning and image processing. The scanning devices capture part geometry and material properties, and processing modules automatically generate accurate junction traces, eliminating the need for manual intervention while improving reliability
Solution Approach 2:
The system creates accurate digital copies (surface models) of the actual parts through scanning. These digital models preserve the exact geometry and material characteristics of physical parts, allowing the system to generate junction traces that faithfully represent the actual assembly state without manual intervention
3Manufacturing precision
If manual inspection and trace establishment are performed, then manufacturing precision is maintained, but productivity deteriorates due to heavy dependence on manpower
Solution Approach 1:
The system enables parts to serve themselves in the inspection and trace establishment process. By scanning parts and automatically analyzing their geometry and material properties, the system eliminates the need for manual inspection while maintaining high precision in junction trace establishment, significantly improving productivity
4Manufacturing precision
If complex processing conditions are accommodated with manual methods, then manufacturing precision is improved, but device complexity increases to achieve automation
Solution Approach 1:
The system employs universal scanning devices and processing modules that can handle various part types, materials, and processing conditions through a single integrated platform. The same core technology (scanning, surface modeling, junction trace establishment) applies across different applications, reducing overall system complexity while maintaining precision
Data Source
AI summary
A system for establishing a junction trace of an assembly includes a surface model creating module, a processing module, and a material inspection module. The assembly includes a first part and a second part assembled with each other. The surface model creating module scans the first part and the second part to separately establish first surface model data and second surface model data. The processing module establishes assembled surface model data according to the first surface model data and the second surface model data, determines a junction region from the assembled surface model data, and determines inspection points mapped on the assembly according to the junction region. The material inspection module inspects materials of the assembly at the inspection points. The processing module establishes a junction trace of the first part and the second part in the assembly according to a material inspection result.