Industrial Machine Setup Verification Using Vision-Guided State Detection
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Solution Overview
Problem
The complex nature of industrial machines makes it difficult and time-consuming to correctly set up and maintain them, as errors in electrical wiring and component placement can go unnoticed, slowing down the setup process and requiring thorough verification.
Innovation Solution
A method using a vision system to identify machine component states and an assistant system to compare these to expected states, allowing for automatic modifications to the machine application to rectify deviations, thereby facilitating faster and easier setup and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a worker manually verifies the correct placement and electrical connection of each machine component, then the reliability of machine setup is improved, but the time required for setup increases significantly
Solution Approach 1:
The patent replaces manual mechanical verification with an automated vision system that uses cameras and image processing to detect machine component states. The system captures images, processes them through neural networks, and automatically identifies component placements and electrical connections, eliminating the need for time-consuming manual inspection while maintaining high reliability.
Solution Approach 2:
The system enables self-verification by having the industrial machine automatically detect and report its own component states. The vision system allows the machine to self-assess its configuration against the electronic plan, automatically identifying deviations without external human intervention, thus improving efficiency while ensuring accuracy.
2Adaptability or versatility
If the number of machine components and electrical connections is increased to provide complex functionality, then the versatility of the industrial machine is improved, but the difficulty of locating errors increases
Solution Approach 1:
The patent implements a feedback mechanism where the vision system continuously monitors machine component states and compares them against the electronic plan. When deviations are detected, the system immediately provides feedback by highlighting the specific erroneous connections or misplaced components, enabling rapid error location regardless of system complexity.
Solution Approach 2:
The system introduces an intermediary layer (the vision system and assistant software) between the complex machine components and the worker. This intermediary automatically processes the complexity by analyzing images, identifying components, and pinpointing errors, thereby simplifying the error-detection task even as machine complexity increases.
3Reliability
If manual verification of each connection is performed thoroughly to ensure correctness, then the reliability of machine operation is improved, but the productivity of the setup process decreases
Solution Approach 1:
The patent applies preliminary action by having the vision system perform verification automatically during the setup process itself, rather than requiring a separate thorough manual check afterward. The system detects and flags errors as components are being installed, allowing immediate correction and eliminating the need for time-consuming post-setup verification.
Data Source
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AI summary
The present invention relates to a method for building and/or maintaining an industrial machine, the machine comprising a plurality of machine components, the industrial machine being controlled by a machine application, wherein - a vision system identifies the states of the machine components, - an assistant system compares the identified states to expected states of the machine components, - in case a deviation of the identified state from the expected state of at least one machine component is detected, then the machine application is modified by the assistant system, preferably automatically, based on the deviating identified state.