Automated LED Validation in Disk Drive Enclosures

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Solution Overview

Problem

The manual validation of light emitting diodes (LEDs) in disk drives within disk processor enclosures (DPEs) or disk array enclosures (DAEs) during manufacturing and integration of computer systems leads to increased testing time, reduced efficiency, and potential human errors due to the need for pausing and restarting automated test scripts.

Innovation Solution

An automated system using a camera to identify and validate LEDs by performing a calibration check, allowing for continuous automated testing without manual intervention, where the camera scans and identifies LEDs on disk drive units within DPEs or DAEs, providing a pass or fail indication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual validation of LEDs is performed during automated testing, then validation accuracy is improved, but testing time increases and efficiency decreases

Engineering Contradiction:

Improvevalidation accuracyVSAvoidtesting time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the manual mechanical inspection process with an automated optical detection system using a camera to capture and analyze LED states. The camera-based system automatically detects LED illumination states, eliminating the need for manual visual inspection while maintaining validation accuracy and enabling continuous automated testing without pauses.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual check of LEDs is introduced, then human error is reduced through careful inspection, but human inconsistencies and errors still arise

Engineering Contradiction:

Improvevalidation consistencyVSAvoidtesting process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual inspection with an automated camera-based detection system that objectively captures LED states. This eliminates human inconsistencies and errors by using standardized image processing algorithms to determine LED validation results, ensuring consistent and reliable validation across all tests without introducing additional process complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If automated test script is paused for manual validation, then thorough checking is achieved, but productivity decreases

Engineering Contradiction:

Improvechecking thoroughnessVSAvoidtesting efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent implements a camera-based automated detection system that captures LED images and processes them through image processing algorithms to determine validation results. This substitution enables thorough checking of LED states while maintaining continuous automated testing flow, eliminating the need to pause the test script and thereby preserving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses a camera to create an optical copy (image) of the LED state, which is then processed automatically through image processing algorithms. This copying approach allows thorough analysis of LED conditions without requiring physical manual inspection, enabling automated decision-making and maintaining testing efficiency.

Inventive Principle:

Principle #26Copying

4Productivity

If camera-based automated detection is implemented, then testing efficiency is improved, but system complexity increases

Engineering Contradiction:

Improvetesting efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent introduces a camera as an intermediary device between the LED subject and the detection system. The camera captures optical images of LED states, which are then processed by image processing algorithms to determine validation results. This intermediary approach enables automated detection with maintained efficiency while managing system complexity through a standardized imaging interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach enables efficient and error-free validation of LEDs, reducing testing time and eliminating human inconsistencies by integrating camera-based identification into the automated testing process, thus enhancing the efficiency of the manufacturing and integration of computer systems.

Implementation Method 1

a camera identifies the DPEs or DAEs and the LEDs

Methodology Applied

Scientific EffectLight detection: Photoelectric Effect

Data Source

PatentUS11682592B2Method and system for automated checking and validation of light emitting diodes on computer systems

Publication Date: 2023.06.20 DELL PROD LP

AI summary

A system, method, and computer-readable medium are disclosed automatic validation of light emitting diodes (LEDs) of disk drives in disk processor enclosures (DPEs) or disk array enclosures (DAEs) during the manufacturing and integration of computer systems. An automated test script is performed in support of the integration of the computer system that includes the LEDs and includes a validation and checking step for the LEDs. A determination is made if a camera is properly calibrated to identify the LEDs as part of the validating and checking step for the LEDs. A DPE or DAE that contains disk drive units that include the LEDs are identified, and an indication is performed as to which LEDs pass or fail.