Portable Tool Location Verification Using Optical Targets
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Solution Overview
Problem
Existing manufacturing systems using portable hand-tools struggle to consistently duplicate exact work across assemblies, as they cannot determine if all fasteners are tightened correctly, in the right sequence, or at the correct locations, lacking the ability to identify the specific article being manufactured based on tool activities and locations.
Innovation Solution
A method and system that establishes defined locations for tool activities, uses a location detector and electrical processor to compare actual and defined locations, verify tool activities, and track data to identify the article being manufactured, incorporating optical targets and cameras for precise location detection and feedback mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If known control systems count the number of times the torque gun reaches the required torque value, then the quantity of fasteners processed is tracked, but the system cannot determine if all fasteners were tightened, if some were tightened twice, or if the fasteners were tightened in a specific sequence
Solution Approach 1:
The patent introduces optical targets as intermediary elements attached to the workpiece at specific fastener locations. These targets serve as mediators between the portable tool and the control system, enabling precise location verification without requiring complex integrated sensing in the tool itself. The camera system captures images of these targets to verify fastener locations, sequences, and completion status.
Solution Approach 2:
The patent replaces mechanical position sensing systems with optical detection. Instead of using complex mechanical encoders or position sensors in the portable tool, the system uses cameras to capture images of optical targets, thereby verifying tool location and fastener completion through optical fields rather than mechanical measurement systems.
2Loss of information
If targets are provided on the workpiece to identify fastener positions and the tool position is sensed, then location accuracy is improved, but the system cannot identify the particular article being manufactured based on tracking actual locations and tool activities
Solution Approach 1:
The patent implements a comprehensive feedback system where the camera captures images of optical targets, the control system processes these images to determine actual tool locations, compares them against defined locations in the program, and provides feedback on whether fasteners were tightened at correct locations, in correct sequences, and whether the correct article is being processed. This feedback loop enables article identification and verification without slowing down the manufacturing process.
3Manufacturing precision
If a worker uses a hand-held tool to carry out manufacturing steps, then operational flexibility is maintained, but the worker cannot consistently duplicate exact work from one assembly to another
Solution Approach 1:
The patent segments the manufacturing verification function into separate components: optical targets are attached to the workpiece, a camera system captures target images, and a control system processes the images to verify locations. This segmentation allows the portable tool to remain simple and easy to operate while the verification infrastructure provides consistent precision across all assemblies.
Data Source
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AI summary
A method of manufacturing an article (12) includes the steps of: establishing a defined location (14) for a tool activity to occur; determining an actual location of the tool (16); comparing the actual location of the tool (16) with the defined location (14); ascertaining an occurrence of the tool activity at the actual location; and verifying whether the tool activity occurred at the defined location.