Mobile Optical Data Capture for Non-Networked Production Equipment
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Solution Overview
Problem
Existing systems face challenges in efficiently capturing data from non-networked production equipment within facilities, leading to friction and potential human errors during manual data entry, especially in environments like pharmaceutical production where security requirements prevent network connectivity.
Innovation Solution
A method utilizing a mobile device equipped with sensors and augmented reality capabilities to automatically detect and capture data from displays on machines within a facility, including augmented reality guidance for operators, and store the data in a procedure file, reducing manual entry and human error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual data entry is used for non-networked production equipment, then data can be captured from equipment displays, but human errors occur during manual entry and operator efficiency is reduced
Solution Approach 1:
The system enables self-service data capture by using the mobile device's camera to automatically detect and read data from equipment displays. The optical sensor captures images of the display, and image processing algorithms automatically extract the data values, eliminating the need for manual transcription and reducing human error while maintaining data accuracy.
Solution Approach 2:
The patent replaces the manual mechanical process of reading and writing data with an automated optical system. The mobile device uses its camera (optical sensor) to capture display information, and software algorithms process the images to extract data, substituting human visual perception and manual entry with machine-based optical recognition and automated data extraction.
2Productivity
If automated data capture using mobile device is implemented, then data capture efficiency is improved and human error is reduced, but device complexity increases
Solution Approach 1:
The system leverages the multi-functionality of a standard mobile device, which already contains a camera, processing unit, and display. By utilizing existing components for data capture purposes rather than requiring dedicated specialized equipment, the system achieves automated data capture efficiency without proportionally increasing overall system complexity.
Solution Approach 2:
The mobile device serves as an intermediary between the production equipment and the data management system. It captures images of equipment displays, processes the data locally, and transmits the extracted information to the appropriate systems, simplifying the overall architecture compared to direct integration while maintaining automated efficiency.
3Extent of automation
If optical sensor is used to detect display data, then automated data extraction is achieved, but measurement precision requirements increase
Solution Approach 1:
The system performs preliminary actions by capturing multiple images and preprocessing them before final data extraction. The mobile device takes photographs of the display, performs initial image processing to enhance quality, and prepares the data for extraction, ensuring that the final measurement achieves the required precision through staged processing.
Solution Approach 2:
The system incorporates feedback mechanisms where the captured images are processed and the extracted data is verified against expected formats and ranges. If the extraction uncertainty exceeds thresholds, the system can request recapture or validation, ensuring measurement precision through iterative verification and feedback loops.
Data Source
AI summary
One variation of a method for automatically capturing data from non-networked production equipment includes: detecting a location of a mobile device within a facility, the mobile device manipulated by an operator while performing a step of an augmented digital procedure at a machine in the facility; estimating a position of a display on the machine relative to a field of view of an optical sensor in the mobile device based on the location of the mobile device and a stored location of the machine within the facility; in response to the position of the display falling within the field of view of the optical sensor, selecting an image captured by the optical sensor; extracting a value, presented on the display, from a region of the image depicting the display; and storing the value in a procedure file for the augmented digital procedure completed at the machine.