Laminate Nonconformance Detection With AI and AR Inspection
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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 comprising a workpiece platform, inspection platform, sensor system, and computer-based analyzer that records layup and inspection information, uses artificial intelligence to predict and identify nonconformances, and displays findings through augmented reality for human operators, enabling real-time adjustments and improved laminate quality.
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 human visual inspection system with an automated optical inspection system comprising cameras, sensors, and image processing algorithms. This substitution eliminates human error and fatigue while maintaining high detection accuracy for nonconformances such as wrinkles, foreign objects, and material handling errors.
Solution Approach 2:
The patent introduces an intermediary automated inspection system that acts as a mediator between the laminate production process and quality control decisions. This intermediary system captures images, processes them through algorithms, and provides objective nonconformance detection, bridging the gap between manufacturing and quality assurance.
2Reliability
If human operators inspect laminates for nonconformances, then nonconformance detection is achieved, but the process is time-consuming and results in higher scrap rates due to delayed identification of issues
Solution Approach 1:
The patent implements preliminary automated inspection immediately after laminate formation but before curing. By detecting nonconformances at this early stage, the system prevents defective laminates from proceeding through the manufacturing process, eliminating time loss associated with post-curing rework or scrap.
Solution Approach 2:
The patent establishes continuous automated inspection throughout the laminate production process, with sensors and cameras operating continuously to monitor each laminate as it is formed. This continuous monitoring eliminates the intermittent nature of manual inspection and ensures no defects go undetected.
3Ease of operation
If visual inspection methods are used to identify nonconformances, then inspection capability is provided, but the process becomes tedious and error-prone, reducing overall manufacturing quality
Solution Approach 1:
The patent enables the inspection system to be self-service through automated image capture, processing, and analysis. The system automatically detects, classifies, and reports nonconformances without requiring human operators to manually examine each laminate, thereby simplifying operation while dramatically improving detection accuracy.
Solution Approach 2:
The patent implements feedback loops where inspection results are immediately communicated back to the manufacturing process. The system provides real-time feedback on detected nonconformances, allowing for immediate corrective actions and continuous process improvement, thereby enhancing both operational simplicity and manufacturing precision.
Data Source
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.