Automatic Screwdriving Control With AI-Based Remote Error Diagnosis
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Solution Overview
Problem
Existing automatic screwdriving machines require expert analysis for error diagnosis, which is costly and time-consuming due to geographical distance, especially when the end customer lacks personnel and resources.
Innovation Solution
A method utilizing artificial intelligence to analyze screwdriving processes remotely through a data processing unit, evaluating data sets transmitted from the machine via the internet, enabling accurate and reliable error identification and optimization without the need for on-site service technicians.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a service technician travels to the end customer's location for error diagnosis and service, then accurate error diagnosis and service can be provided, but time and costs increase significantly due to geographical distance
Solution Approach 1:
The patent replaces the mechanical system of physical travel by service technicians with an electronic data transmission system. Screwdriving data is captured by sensors during the screwing process, transmitted digitally via network to a remote evaluation server, and analyzed automatically, eliminating the need for physical presence while maintaining diagnostic accuracy.
Solution Approach 2:
The patent introduces an intermediary data transmission and evaluation system between the screwdriving machine and the service expert. A data transmission unit captures screwdriving parameters, transmits them through a network intermediary to a remote server, where evaluation software analyzes the data and provides diagnostic results, serving as a digital mediator that bridges the gap between remote locations.
2Reliability
If a service technician travels to the end customer's location for error diagnosis and service, then accurate error diagnosis and service can be provided, but costs increase due to travel expenses and service appointment logistics
Solution Approach 1:
The patent replaces the energy-consuming mechanical travel system with a low-energy electronic data communication system. Instead of technicians traveling across geographical distances consuming fuel and resources, the system uses digital data transmission over networks, dramatically reducing energy consumption and associated costs while maintaining service quality.
Solution Approach 2:
The patent creates a digital copy of the screwdriving process data that can be transmitted and analyzed remotely. The screwdriving parameters, torque curves, and process data are captured as digital replicas of the actual screwing process, allowing remote evaluation without physical presence, thereby eliminating travel costs while preserving diagnostic accuracy.
3Productivity
If screwdriving data is transmitted and evaluated remotely using artificial intelligence, then time and costs are reduced, but the system complexity increases
Solution Approach 1:
The patent segments the service system into distinct functional modules: a data capture unit in the screwdriving machine, a data transmission unit for communication, and a remote evaluation unit with analysis software. This segmentation allows each component to be developed and maintained independently, managing overall system complexity while enabling remote high-efficiency service.
Solution Approach 2:
The patent employs an intermediary evaluation server that handles the complex AI-based data analysis remotely. The complexity of artificial intelligence algorithms and large data processing is isolated in the cloud-based server, keeping the local screwdriving machine simple while enabling advanced productivity-enhancing analytics through the intermediary system.
Data Source
AI summary
The invention relates to a method for controlling an automatic screwdriving machine that comprises: a screwdriving unit for the automated screwing of a screw into a component; and a control unit for controlling the screwdriving unit based on a screwdriving program that is stored in the control unit and that defines the time development of a desired rotational speed at which the screw is to be driven during the screwdriving process and, optionally, also defines the time development of a feed force to be exerted on the screw during a screwdriving process, wherein, during a screwdriving process, the control unit records a data set that relates to the screwdriving process and that comprises the time developments of the following screwdriving parameters: an actual rotational speed of the screw, a torque exerted on the screw, a feed position of the screw and a feed speed of the screw. The control unit transmits the recorded data set to a remote data processing unit in which the screwdriving process is evaluated by means of artificial intelligence based on the transmitted data set.