3D-Guided Sensor Positioning for Manual Workpiece Inspection
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Solution Overview
Problem
Existing methods for robotic inspection of workpieces are inadequate for manual inspection by operators, as they rely on operator experience for sensor positioning, leading to inefficient defect detection.
Innovation Solution
An inspection assistance device that includes a 3D scanner to acquire real data of the workpiece, a conversion unit to align design and real data, and a display control unit to guide sensor movement within allowable deviations, enabling efficient manual inspection by operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an operator manually positions a sensor for inspection based on experience, then the inspection can be performed flexibly, but the positioning accuracy and efficiency deteriorate
Solution Approach 1:
The patent introduces a display device as an intermediary between the inspection system and the operator. The display device provides visual guidance (arrows and displays) that mediates the operator's manual sensor positioning, transforming experience-based positioning into guidance-based positioning while maintaining manual flexibility
Solution Approach 2:
The system implements feedback by displaying the current sensor position relative to the target position and providing directional guidance. The display device continuously updates the operator on positioning status, enabling real-time correction and precise positioning without requiring extensive operator experience
2Ease of operation
If an operator manually positions a sensor for inspection, then operational flexibility is maintained, but inspection efficiency deteriorates
Solution Approach 1:
The display device serves as an intermediary that enhances manual operation efficiency by providing real-time visual feedback and directional guidance, allowing operators to perform manual inspections more efficiently without automation
Solution Approach 2:
The patent replaces experience-based manual positioning with a guidance system that uses visual displays and directional indicators. This substitution transforms the operational method from skill-dependent to system-guided, significantly improving inspection efficiency while maintaining manual operation flexibility
3Productivity
If robotic automation is used for inspection, then inspection efficiency improves, but the method cannot be applied to manual inspection by operators
Solution Approach 1:
The patent creates a universal guidance system that can support both manual and automated inspection methods. The display device and positioning guidance mechanism serve multiple functions, providing visual feedback that is applicable regardless of whether the sensor is manually or robotically positioned
Solution Approach 2:
The system introduces a display-mediated guidance layer that bridges manual operation and automated control. This intermediary guidance mechanism can be applied to both manual sensor positioning by operators and robotic sensor positioning, making the inspection method universally applicable
Data Source
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AI summary
An operator is enabled to efficiently inspect a workpiece. An inspection assistance device includes a real data acquisition unit configured to acquire real data indicating a shape, a position, and an orientation of a workpiece placed in a real space, a conversion unit configured to calculate an inspection position on the workpiece in the real space by performing a conversion operation of superimposing design data indicating a design shape of the workpiece on the real data on an inspection position on the design data, a sensor position acquisition unit configured to acquire a position of a sensor that inspects the workpiece in the real space, and a display control unit configured to cause a display device to display a direction in which a difference between the inspection position on the workpiece in the real space and the position of the sensor falls within an allowable positional deviation range as a direction in which the sensor is to be moved.