Common Optical Measurements Across Multiple Assembly Units
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Solution Overview
Problem
Current optical inspection systems lack the ability to automatically generate a common measurement across multiple assembly units and efficiently configure optical inspection stations along an assembly line, leading to inefficiencies in defect detection and quality control.
Innovation Solution
A method that involves retrieving images from optical inspection stations, identifying serial numbers and positions of units and stations, and generating a virtual representation of the assembly line, including the positions of optical inspection stations and units, to automatically configure and monitor the assembly line in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual configuration and measurement methods are used for optical inspection stations, then setup time and calibration effort are reduced, but measurement consistency and automation capability across multiple assembly units deteriorate
Solution Approach 1:
The system creates a virtual representation (copy) of the assembly line that mirrors the physical layout. This virtual model allows automatic measurement generation and analysis without interfering with the physical inspection stations, enabling automation while keeping the physical system configuration simple.
Solution Approach 2:
A virtual representation acts as an intermediary between the physical inspection stations and the measurement analysis system. This intermediary layer enables automatic measurement generation by translating physical station data into a standardized virtual format, resolving the contradiction between automation and complexity.
2Reliability
If multiple optical inspection stations are deployed along the assembly line, then defect detection coverage is improved, but real-time monitoring and coordination between stations become more difficult
Solution Approach 1:
The system segments the assembly line into multiple virtual inspection stations, each representing a physical station. This segmentation allows independent configuration and monitoring of each station while maintaining overall system coordination through the unified virtual representation, improving both defect detection coverage and operational ease.
Solution Approach 2:
By creating a virtual copy of the multi-station assembly line, the system enables centralized monitoring and coordination of all inspection stations. The virtual representation consolidates data from multiple stations, making real-time monitoring easier while maintaining comprehensive defect detection coverage.
3Productivity
If manual measurement and defect identification processes are used, then system complexity is reduced, but productivity and quality control efficiency deteriorate
Solution Approach 1:
The system enables self-service quality control by automatically generating measurements and identifying defects without manual intervention. The virtual representation automatically processes inspection data, generates measurements, and flags defects, significantly improving quality control efficiency while the automated processes manage the system complexity.
Solution Approach 2:
The system replaces manual mechanical measurement processes with automated optical inspection and virtual representation analysis. This substitution eliminates manual measurement operations, improving productivity and quality control efficiency while the automated digital system manages the complexity of measurement and analysis operations.
Data Source
AI summary
A method includes: displaying a first image of a first assembly unit within a user interface; locating a first virtual origin at a first feature on the first assembly unit; displaying a first subregion of the first image within the user interface responsive to a change in a view window of the first image; recording a geometry and a position of the first subregion relative to the first virtual origin; locating a second virtual origin at a second feature—analogous to the first feature—on a second assembly unit represented in the second image; projecting the geometry and the position of the first subregion onto the second image according to the second virtual origin to define a second subregion of the second image; and, in response to receipt of a command to advance from the first image to the second image, displaying the second subregion within the user interface.