Resonance Inspection Feedback for Part Production Control
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Solution Overview
Problem
Current part production processes lack effective methods to monitor and control manufacturing defects and in-service damage through vibrational data, leading to inconsistent part quality and increased production of non-compliant parts.
Innovation Solution
The use of vibrational inspection techniques, specifically resonance inspection, to acquire and analyze vibrational data from parts, correlating response characteristics to process variables, allowing for real-time feedback and adjustment of production controls to improve process consistency and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used without vibrational monitoring, then production speed is maintained, but part quality consistency deteriorates and manufacturing defects increase
Solution Approach 1:
The system implements real-time feedback by continuously acquiring vibrational data from parts during production, comparing it to reference data, and automatically generating control signals to adjust manufacturing parameters. This closed-loop feedback mechanism maintains part quality consistency without requiring reduction in production speed, as the monitoring and adjustment occur in real-time during normal production flow.
Solution Approach 2:
The patent replaces traditional mechanical measurement and quality inspection methods with vibrational analysis using acoustic and ultrasonic techniques. By substituting physical contact measurement with resonance-based detection, the system achieves continuous quality monitoring without mechanical intervention that would slow production, thereby maintaining productivity while improving manufacturing precision.
2Manufacturing precision
If vibrational inspection is implemented for process control, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The system achieves multi-functionality by using a single vibrational inspection platform to perform multiple tasks: quality acceptance determination, process variable monitoring, and real-time control adjustments. This universal approach consolidates what would otherwise require separate inspection and control systems, reducing overall device complexity while maintaining high manufacturing precision through comprehensive vibrational analysis.
Solution Approach 2:
The system incorporates automatic self-adjustment capabilities where the comparison of vibrational data to reference data automatically generates control signals without requiring manual intervention. This self-service feature reduces the complexity of operator training and system management, as the system autonomously performs data analysis, defect detection, and parameter adjustment based on pre-established reference standards.
3Manufacturing precision
If real-time vibrational monitoring is used, then manufacturing precision improves, but loss of time increases due to data acquisition and analysis
Solution Approach 1:
The system maintains continuous vibrational monitoring throughout the production process without interrupting manufacturing operations. By continuously acquiring and analyzing vibrational data in real-time, the system eliminates the need for separate inspection stages that would cause production delays, thereby maintaining manufacturing precision while minimizing time loss through uninterrupted production flow.
Solution Approach 2:
The system performs rapid vibrational analysis by comparing acquired data against pre-established reference data using efficient algorithms. This rushing through the data processing step using optimized comparison methods enables quick defect identification and immediate control adjustments without significant time penalty, maintaining both high manufacturing precision and production speed.
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
This approach enables the monitoring of part production processes to identify trends and adjust controls before parts become non-compliant, ensuring consistent part quality and reducing the number of defective parts produced by correlating vibrational data with process variables.
Implementation Method 1
vibrational data for at least a first part produced by the part production process. The vibrational data includes a frequency response of the first part when excited at a plurality of input frequencies
Implementation Method 2
Resonance inspection is a proven non-destructive method for the evaluation of stiff components. Resonance inspection may be provided by impulse-induced vibration, swept-sine wave stimulation, and other acoustic or ultrasonic techniques in which a part under test is vibrated and the vibrational response of the part is measured
Data Source
AI summary
Generation of feedback for a part production process based on vibrational testing of parts produced by the part production process. A response characteristic may be identified from vibrational data regarding the parts that is correlated to a process variable of the part production process. The response characteristic may relate to a state of the process variable such that identification of the response characteristic may allow for generation of feedback regarding adjustment of a process control. Such response characteristic may relate to a vibrational metric regarding vibrational data and may comprise identifying a trend in data between a plurality of parts. Also presented are approaches to evaluation of parts, including batch evaluation of parts in which collective vibrational data regarding a plurality of parts belonging to a batch are analyzed. The process control aspects may be performed independently or in combination with part evaluation.