Mixed Reality Component Assembly Verification System
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Solution Overview
Problem
In component assembly, large or remotely produced components pose challenges for pre-assembly verification, leading to delays and increased inspection costs due to difficulties in confirming assembly compatibility before actual assembly, and existing methods burden workers with physical and mental strain from paper-based instructions and visual line movement.
Innovation Solution
A mixed reality technology-based component assembly work support system that images the workspace, generates virtual images of components based on 3D data, and superimposes them onto real images, allowing workers to verify assembly quality without physical component interaction and integrating assembly procedures directly into the composite image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are abutted in advance to confirm assembly compatibility, then assembly problems can be detected early, but it becomes impossible when components are too large to move or stored in different locations
Solution Approach 1:
The patent creates a virtual copy of the component to be assembled and superimposes it onto the real component in the worker's field of view. This virtual component contains all geometric and dimensional information, allowing assembly compatibility verification without physically moving or transporting actual components. The virtual image is generated from 3D data and displayed through a head-mounted display device.
2Reliability
If inspection conditions are made stricter to detect assembly problems early, then quality improves, but inspection cost increases
Solution Approach 1:
Instead of performing strict physical inspections with specialized facilities at multiple locations, the patent uses virtual imaging to superimpose the virtual component onto the real component. This allows comprehensive assembly verification using existing standard facilities, dramatically reducing inspection costs while maintaining or improving quality.
Solution Approach 2:
The patent replaces complex mechanical inspection systems and facilities with a virtual reality-based visual verification system. The head-mounted display and virtual image generation substitute for expensive dimensional measuring units and inspection facilities, making quality verification accessible without heavy infrastructure.
3Loss of information
If assembly instructions are provided on paper or tablets, then workers have reference materials, but visual line movement increases and physical/mental burden increases
Solution Approach 1:
The patent merges the assembly instructions with the visual field by displaying them directly in the head-mounted display alongside the virtual and real components. Workers can see both the component assembly guidance and the actual/virtual components simultaneously without shifting their gaze between separate instruction manuals and workpieces, eliminating unnecessary visual line movement and reducing physical and mental burden.
Data Source
AI summary
The system includes imaging unit which images a work space at a viewpoint position in a visual line direction of a worker together with an other component to which one component is to be installed, a position attitude information obtaining unit which obtains position attitude information which indicates relative position attitude relation between viewpoint of the worker and other component in the work space, a virtual image generating unit which generates virtual image of an actual shape of the one component at the viewpoint position in the visual line direction of the worker based on position attitude information, an image composing unit which generates composite image by superimposing virtual image on a real image in the work space imaged by the imaging unit, and display unit which displays composite image. According to the system, efficiency of component assembly work can be considerably improved by using mixed reality technology.