Mobile Imaging Diagnostics for Industrial Automation Inspection
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Solution Overview
Problem
Existing inspection systems for industrial automation devices are expensive, inflexible, require specialized training, and produce higher resolution data than necessary, often needing specific operating conditions.
Innovation Solution
Utilize mobile devices equipped with sensors and processing capabilities for initial diagnostic inspections, allowing inspectors to perform inspections using mobile devices that can scan barcodes, take photos or videos, and collect data such as vibration and temperature, with analysis performed on the device or sent to another device for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection systems are used, then inspection accuracy and reliability are improved, but cost and device complexity increase significantly
Solution Approach 1:
The mobile computing device performs multiple inspection functions using a single integrated platform. The device combines camera, microphone, temperature sensor, vibration sensor, and processing capabilities to conduct various types of inspections (visual, audio, thermal, vibrational) without requiring separate specialized equipment for each inspection type.
Solution Approach 2:
The system creates a digital copy of the physical inspection process by capturing images, audio recordings, and sensor data that replicate traditional inspection methods. These digital copies are then processed and analyzed to determine equipment condition, replacing the need for physical measurement tools while maintaining inspection accuracy.
2Measurement precision
If traditional inspection systems are used, then inspection precision is improved, but cost increases
Solution Approach 1:
The system replaces expensive, durable specialized inspection equipment with affordable mobile computing devices that can be widely distributed. While mobile devices have shorter operational lifetimes in harsh industrial environments compared to dedicated inspection equipment, their low cost allows for replacement and widespread deployment without significant investment.
Solution Approach 2:
The system changes the operational parameters of standard mobile device sensors to optimize them for industrial inspection purposes. By adjusting sampling rates, sensitivity thresholds, and processing algorithms, the system achieves inspection-level precision from consumer-grade sensors without requiring expensive specialized equipment.
3Manufacturing precision
If traditional inspection systems are used, then inspection quality is improved, but ease of operation deteriorates due to specialized training requirements
Solution Approach 1:
The mobile device inspection system performs automated analysis of captured data using onboard processing and algorithms. The device automatically identifies anomalies, compares measurements against thresholds, and generates inspection results without requiring operator interpretation, thereby maintaining high inspection quality while eliminating the need for specialized training.
Solution Approach 2:
The system replaces manual inspection procedures requiring trained operators with automated digital analysis. Machine learning algorithms and processing software substitute for human expertise in interpreting sensor data, allowing untrained operators to conduct high-quality inspections by simply capturing data with the mobile device.
4Measurement precision
If traditional inspection systems are used, then data resolution is improved, but adaptability deteriorates due to fixed installation requirements
Solution Approach 1:
The inspection system transitions from static, fixed installations to dynamic, mobile deployment. The mobile computing device can be moved to different locations, adjusted to various angles, and repositioned as needed during inspection, providing adaptability while maintaining data quality through controlled capture procedures and multiple measurement points.
Solution Approach 2:
The system divides the inspection process into discrete capture events rather than requiring continuous fixed monitoring. The mobile device captures data at specific moments and locations, segmenting the inspection into manageable discrete measurements that can be aggregated to achieve comprehensive coverage and high effective resolution.
Data Source
AI summary
A method includes receiving an indication of an inspection of an industrial automation device being triggered, displaying, via a display of a mobile computing device, instructions for performing the inspection of the industrial automation device, receiving, via one or more sensors of the mobile computing device, one or more sensors communicatively coupled to the mobile computing device, or both, inspection data associated with the industrial automation device, processing the inspection data associated with the industrial automation device to generate results of the inspection of the industrial automation device, and displaying, via the display of the mobile computing device, the results of the inspection of the industrial automation device.