Optical 3D Inspection With AR Feedback for Machined Parts
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Solution Overview
Problem
Current quality inspection methods for machined parts are inefficient, imprecise, and not suitable for widespread industrial use due to reliance on manual tools and limited availability of coordinate measurement machines (CMMs) on shop floors, which are restricted to three-dimensional measurements and require extensive programming for complex components.
Innovation Solution
A system and method utilizing optical tracking and augmented reality to generate synchronized measurement data, allowing for precise three-dimensional measurements of components using a measurement device coupled with an optical marker device and cameras, enabling automated or semi-automated data acquisition and feedback for efficient quality inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual measurement tools (calipers, scales) are used for quality inspection, then the inspection can be performed anywhere, but the measurement precision and speed are slow and imprecise
Solution Approach 1:
The patent replaces manual mechanical measurement tools (calipers, scales) with an optical measurement system consisting of cameras, optical markers, and computer vision algorithms. This substitution eliminates the need for physical contact tools while providing high-precision three-dimensional measurements, resolving the contradiction between measurement accessibility and measurement precision.
2Measurement precision
If coordinate measurement machines (CMM) are used for high-precision measurement, then measurement precision is high, but the device complexity and cost increase making them unsuitable for shop floor deployment
Solution Approach 1:
The patent replaces complex mechanical CMM systems with an optical-based measurement system using cameras and optical markers. This substitution reduces mechanical complexity while maintaining high measurement precision, enabling deployment on shop floors rather than restricting use to controlled laboratory environments.
Solution Approach 2:
The patent uses optical markers that create visual copies or representations of measurement points on the component. Cameras capture images of these markers, and software processes the visual information to derive precise three-dimensional coordinates, eliminating the need for complex physical measurement probes and mechanisms.
3Extent of automation
If CNC machines with robotics are used for measurement of complex components, then automation capability is improved, but extensive programming efforts increase device complexity and reduce ease of deployment
Solution Approach 1:
The patent uses optical markers as visual copies that cameras can automatically detect and track. This approach eliminates the need for complex robotic programming because the system passively captures marker positions through imaging, automatically processes the visual data, and generates measurement results without extensive coding or manual intervention.
Solution Approach 2:
The measurement system is self-sufficient in automatically detecting optical markers, calculating three-dimensional positions, and generating inspection reports. The system does not require external robotic arms or complex programming to position measurement tools, as the optical markers themselves provide the measurement information that the camera system automatically processes.
4Device complexity
If traditional quality inspection methods are used, then the process is simple, but productivity is low and inspection is unwieldy and expensive
Solution Approach 1:
The patent replaces slow manual measurement processes with automated optical measurement systems. Multiple cameras can simultaneously capture images of multiple optical markers on a component, enabling parallel processing of multiple measurement points. This dramatically increases inspection speed and productivity while keeping the overall process relatively simple through automated image processing algorithms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate, efficient, and error-free quality inspection of complex components by allowing measurements to be taken in any order, reducing labor and enhancing precision, and making high-precision measurement technology accessible on shop floors.
Implementation Method 1
generating co-ordinate data of the measurement device, using the optical marker device and at least one camera
Data Source
AI summary
A method for inspecting a component includes generating measurement data of the component, using a measurement device coupled to an optical marker device 502. The method further includes generating co-ordinate data of the measurement device, using the optical marker device and at least one camera 504. The method includes generating synchronized measurement data based on the measurement data and the co-ordinate data 506. The method further includes retrieving pre-stored data corresponding to the synchronized measurement data, from a database 508. The method also includes generating feedback data based on the pre-stored data and the synchronized measurement data, using an augmented reality technique 510. The method includes operating the measurement device based on the feedback data to perform one or more measurements to be acquired from the component 512.