Laminate Nonconformance Detection With AI and AR Feedback
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Solution Overview
Problem
Current methods for detecting nonconformances in laminates are tedious, error-prone, and rely heavily on human skill, leading to increased scrap rates due to inefficiencies in identifying issues such as wrinkles, foreign objects, or material handling errors during the layup process.
Innovation Solution
A nonconformance management system that includes a workpiece platform, inspection platform, sensor system, and analyzer in a computer system, which records layup and inspection information, uses artificial intelligence to identify nonconformances, and displays this information through an augmented reality display for human operators, allowing for real-time correction and reduction of scrap rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If human operators perform visual inspections to detect nonconformances in laminates, then inspection capability is provided, but the process becomes tedious, error-prone, and relies heavily on human skill leading to increased scrap rates
Solution Approach 1:
The patent replaces the mechanical visual inspection system performed by human operators with an automated optical inspection system using cameras and image processing algorithms. This substitution eliminates human error and fatigue while maintaining continuous inspection capability, directly resolving the contradiction between reliability and productivity in nonconformance detection.
Solution Approach 2:
The inspection system performs self-identification of nonconformances through automated image capture and analysis. The system independently detects, classifies, and flags defects without requiring human intervention for each inspection decision, enabling continuous operation at full production speed while maintaining high detection accuracy.
2Measurement precision
If human operators inspect laminates for nonconformances, then nonconformance detection is performed, but the process is time-consuming and leads to increased scrap rates
Solution Approach 1:
The automated inspection system operates continuously throughout the laminate manufacturing process, capturing images at multiple stages (layup, curing, final inspection). This continuous inspection eliminates the time loss associated with intermittent manual inspections while maintaining consistent detection precision through algorithmic analysis of every laminate produced.
Solution Approach 2:
The system performs preliminary detection of nonconformances during the manufacturing process itself, identifying defects early when they can be addressed before final production. This preliminary action prevents time loss in later rework or scrap processing while maintaining accurate detection through multi-stage imaging.
3Ease of operation
If visual inspection methods are used to identify nonconformances, then inspection capability is provided, but the process is tedious and error-prone
Solution Approach 1:
The patent replaces the complex, skill-dependent human visual inspection process with a standardized automated optical system. The camera-based system with programmed image processing algorithms provides consistent, repeatable detection performance that does not vary with operator fatigue or skill level, directly resolving the contradiction between operational simplicity and detection reliability.
Solution Approach 2:
The inspection system provides immediate feedback through automated flagging and classification of detected nonconformances. The system consistently applies the same detection criteria to every laminate, providing reliable and repeatable results that are immediately actionable, eliminating the variability inherent in manual inspection processes.
Data Source
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AI summary
A method, apparatus, and system for managing nonconformances in laminates. A nonconformance management system comprises a sensor system and an analyzer in a computer system. The sensor that records layup information about the layup of layers on a workpiece platform and records inspection information about the laminate located on an inspection platform, wherein the laminate is formed from curing the workpiece. The analyzer in the computer system identifies a laminate nonconformance in the laminate using the inspection information, generates nonconformance information about the laminate nonconformance, and displays the nonconformance information about the laminate nonconformance on the laminate using a display system for an augmented reality display.