Light-Guided Assembly Projection for Accurate Task Completion
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Solution Overview
Problem
Manufacturing and assembly processes face challenges in ensuring accurate and efficient completion of operational steps within standard time allowances, leading to costly bottlenecks and excess inventory due to improper workmanship and time deviations.
Innovation Solution
A light-guided assembly system that projects visual indicators onto physical objects, using a guide system controller interfaced with a manufacturing execution system and sensor apparatus to provide directional light projections and confirm action completion, while recording images and cycle times for process improvement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If visual indicators are projected onto physical objects to guide operators, then manufacturing precision and task completion accuracy are improved, but device complexity increases due to projection systems and controllers
Solution Approach 1:
The patent uses projection systems to create visual copies or representations of the physical object and its required assembly steps directly onto the work surface. The controller projects images that replicate the object's features and guide indicators, allowing operators to see virtual overlays on the physical workspace without adding complex mechanical guidance systems.
Solution Approach 2:
The invention replaces traditional mechanical guidance systems (such as physical fixtures, templates, or automated positioning mechanisms) with an optical projection system. The controller uses software-driven image projection to provide guidance, substituting complex mechanical structures with a more flexible and simpler optical-electronic system.
2Productivity
If projection systems are used to guide assembly steps, then productivity and cycle time are improved, but use of energy increases due to continuous operation of projectors and controllers
Solution Approach 1:
The projection system operates periodically rather than continuously, activating only when needed for specific assembly steps or when the controller detects that guidance is required. The system can pause or dim projections during periods when the operator is not actively working on a step, reducing overall energy consumption while maintaining productivity during active work periods.
Solution Approach 2:
The system dynamically adjusts projection parameters such as brightness, contrast, and projection duration based on environmental conditions and operational needs. The controller modifies these parameters to provide adequate guidance while minimizing energy consumption, such as reducing brightness in well-lit areas or extending projection duration only when task completion is anticipated.
3Adaptability or versatility
If multiple addressed display features are projected at different locations, then adaptability and versatility are improved, but device complexity and cost increase
Solution Approach 1:
The projection system uses a single multi-functional controller that can project multiple different types of visual indicators (such as location markers, step numbers, warnings, and instructional text) onto various locations of the physical object. This universal controller replaces the need for multiple specialized projection devices, achieving versatility while actually reducing overall system complexity and cost.
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
The system effectively guides operators through accurate and timely completion of tasks, reducing errors and cycle times, and providing a cost-effective method for ensuring proper assembly processes.
Implementation Method 1
A light-guided assembly system that projects visual indicators onto physical objects
Data Source
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Figure 1A~1L
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AI summary
A guide system and method of projecting visual indicators onto a physical object to guide actions of an individual comprises providing a guide system (200) having a guide system controller (220) and a projector (266), with the guide system controller including a plurality of addressed display features (286). An input signal (207) is provided to the guide system controller (220) whereby an addressed display feature is selected based on the input signal and the projector (266) projects a visual indicator corresponding to the selected addressed display feature onto a physical object. The guide system controller (220) may also include a plurality of positional identifiers (288), with the method including the selecting of a positional identifier based on the input signal and the projecting of the visual indicator onto a physical object at a location corresponding to the selected positional identifier.