Remote Workpiece Inspection Using Image Templates and Expert Feedback
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Solution Overview
Problem
In manufacturing and maintenance processes, especially in fields like aerospace and electronics, the requirement for skilled inspectors to be present at multiple facilities leads to underutilization and increased costs, while errors in recording component identifiers can result in safety issues and inefficiencies, particularly when transferring product manufacturing or performing repairs.
Innovation Solution
A system and method utilizing a database to store inspection templates and a workpiece data capture device that allows inspectors to remotely review captured images and data from workers, enabling efficient inspection, diagnosis, and maintenance, even when inspectors and workers are geographically dispersed, with features like augmented reality annotations and real-time feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If skilled inspectors are deployed to multiple facilities to perform inspections, then inspection quality and correctness are improved, but inspector utilization efficiency deteriorates and costs increase
Solution Approach 1:
The patent creates digital copies of inspection data, component identifiers, and workpiece information that can be accessed and verified by inspectors at any location. Instead of requiring physical presence at multiple facilities, the system captures data electronically (photos, videos, text) and transmits it to inspectors who review remotely, eliminating the need for inspectors to travel between facilities while maintaining inspection quality.
Solution Approach 2:
The patent introduces a communication system and database as intermediaries between workers at facilities and inspectors. The system captures workpiece data, stores component identifiers in a database, and transmits this information to inspectors who then provide guidance back to workers. This intermediary system enables remote inspection while maintaining the quality that would otherwise require physical inspector presence.
2Reliability
If multiple trained inspectors are required at each facility, then inspection coverage is improved, but training costs and operational complexity increase
Solution Approach 1:
The patent creates a universal inspection system that can serve multiple facilities through a centralized database and communication network. A single inspector can access and verify data from any facility, making the inspection capability universal rather than facility-specific. This eliminates the need for each facility to maintain its own trained inspectors while ensuring consistent inspection coverage across all locations.
3Ease of manufacture
If component identifiers are recorded manually during assembly, then manufacturing process flexibility is improved, but recording accuracy deteriorates and errors increase
Solution Approach 1:
The patent implements feedback mechanisms where inspectors verify component identifiers and provide corrections or confirmations back to the manufacturing process. The system captures identifier data, transmits it to inspectors for verification, and uses their feedback to confirm accuracy or request corrections. This feedback loop maintains manufacturing flexibility while significantly improving recording accuracy through expert verification.
Solution Approach 2:
The patent replaces manual mechanical recording processes with electronic data capture and transmission systems. Instead of physically writing down component identifiers, the system uses electronic sensors, cameras, and databases to capture and store identifier information, then transmits it electronically to inspectors for verification. This substitution eliminates manual errors while maintaining process flexibility.
4Reliability
If experts are required at maintenance facilities for diagnosis, then diagnostic accuracy is improved, but expert utilization efficiency deteriorates
Solution Approach 1:
The patent creates digital copies of workpiece data, diagnostic information, and visual evidence that can be transmitted to experts for remote review. Instead of requiring experts to physically travel to maintenance facilities, the system captures diagnostic data electronically and transmits it to experts who provide their expertise remotely, maintaining diagnostic accuracy while dramatically improving expert utilization efficiency.
Data Source
AI summary
A system and method for inspection maintenance and/or diagnosis of a variety of workpieces is provided. The system serves workers working on a workpiece, inspectors who are distal from the workers and/or can be used for remote training or for advanced diagnosis and/or repair. The system preferably includes a template of a set of one or more predefined required images of a workpiece required by an inspector to perform their inspection or diagnosis. The set of predefined required images is provided to the worker. The worker captures the images with an appropriate workpiece data capture device and provides them to the inspector for review. The inspector examines the provided images and either approves the workpiece based on their content, requests additional images for further examination and/or provides annotations and other information to the worker to address identified issues. The system maintains a database of all images and information.