Portable Vision Inspection for Consistent Vehicle Quality Checks

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Solution Overview

Problem

Vehicle manufacturing processes face challenges in quality monitoring due to subjective manual checks and time-consuming machine learning-based machine vision inspections, which are difficult to implement in conventional systems.

Innovation Solution

A system comprising a station information system, a portable vision system, and a quality monitoring system that includes a user interface, imaging devices, and quality check modules to automate quality checks, using machine learning models for defect detection and communicating via a common data protocol.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual quality checks are performed by operators, then flexibility and adaptability are maintained, but subjectivity and human error increase reducing reliability

Engineering Contradiction:

Improvequality check accuracyVSAvoidmanual inspection level

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The patent replaces manual visual inspection with an automated imaging device that captures images of components. The imaging device systematically records visual data without human subjectivity, and the captured images are processed by a defect detection model to identify defects objectively, thereby substituting the mechanical human inspection process with an automated optical system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-inspection where the imaging device captures images and the defect detection model automatically analyzes them without requiring operator intervention. The quality check process serves itself through automated defect identification and notification, eliminating the need for human operators to perform visual inspections.

Inventive Principle:

Principle #25Self-service

2Reliability

If machine learning-based machine vision inspections are implemented, then objectivity and reliability improve, but implementation complexity and time consumption increase

Engineering Contradiction:

Improvequality check consistencyVSAvoidsystem implementation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the quality inspection system into distinct functional modules: an imaging device for image capture, a defect detection model for analysis, and a notification system for results communication. This segmentation allows each component to be independently configured and trained, reducing overall system complexity while maintaining machine learning-based defect detection capabilities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The defect detection model is designed to be universally applicable across different component types and manufacturing stations. The model can be trained on various datasets and deployed to multiple imaging devices throughout the manufacturing process, providing consistent defect detection functionality without requiring separate systems for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If traditional machine vision systems are deployed, then automated defect detection capability is achieved, but integration difficulty and deployment time increase

Engineering Contradiction:

Improvequality check speedVSAvoidmachine learning training time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The defect detection model is trained in advance on comprehensive datasets representing various defect types and conditions before deployment. This preliminary training ensures the model is ready for immediate use when deployed to manufacturing stations, eliminating the need for time-consuming on-site training and enabling rapid integration into existing production lines.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If portable vision systems are used at manufacturing stations, then inspection flexibility improves, but system coordination and data management complexity increase

Engineering Contradiction:

Improvestation mobilityVSAvoidsystem coordination complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The notification system serves as an intermediary between the portable imaging devices and the central quality monitoring system. It receives images from various stations, coordinates with the defect detection model, and communicates results back to the appropriate stations, simplifying the coordination complexity of multiple portable devices while maintaining system-wide integration.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12510492B2System for monitoring vehicle manufacturing process employing portable vision system and quality monitoring system

Publication Date: 2025.12.30 FORD GLOBAL TECH LLC

AI summary

A system includes a station information system, a portable vision system, and a quality monitoring system. The station information system includes a station computing device configured to provide a notification related to a manufacturing operation performed on a component. The portable vision system includes a quality check module configured to include a station task module configured to execute a quality check task based on an image. The quality monitoring system includes a quality monitoring computing device configured to request the portable vision system to execute the quality check task based on a trigger message from the station information system and to provide a task data message related to the quality check task executed by the portable vision system to the station information system. The station computing device is configured to provide the notification based on the task data message from quality monitoring system via the user interface device.