Tool training for automated tool control systems
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Solution Overview
Problem
Current inventory control systems for tools, especially in manufacturing and aerospace industries, face challenges such as the need for simplified tool training, reduced time in processing tool data, and automation of foam changeout processes, as well as errors from manual data entry and sensor malfunctions, which affect accuracy and efficiency.
Innovation Solution
An image-based inventory control system that captures and processes images of storage locations to determine tool presence and absence, simplifies the tool training process, automates the foam changeout process, and updates the system database, using image sensing devices and data processors to generate adjusted image data for inventory determination and foam layer production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are disposed in numerous storage locations to detect tool presence, then inventory detection capability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent uses image-based copying to represent physical tool presence. Instead of placing sensors in each storage location, a single image capture device creates visual copies (images) of tools in their storage locations. The image processing system analyzes these visual copies to determine tool presence, replacing numerous physical sensors with optical copying and digital analysis.
2Measurement precision
If manual inventory checks are performed to ensure tool accountability, then inventory accuracy is improved, but loss of time increases
Solution Approach 1:
The patent replaces manual mechanical inventory checking with an automated image-based system. Image capture devices automatically photograph storage locations, and computer processing automatically analyzes these images to determine tool presence and generate inventory reports. This substitution eliminates manual labor while maintaining high accuracy through automated image recognition and analysis.
3Reliability
If random audits are conducted to prevent tool theft and misplacement, then inventory security is improved, but productivity decreases due to operational interruptions
Solution Approach 1:
The patent enables continuous inventory monitoring without interrupting manufacturing operations. The image capture device continuously or periodically captures images of storage locations, and the system continuously processes these images to track tool movement and generate alerts. This continuous monitoring provides ongoing security and accountability without requiring periodic shutdowns for manual audits.
4Measurement precision
If image-based inventory determination is implemented to identify tool presence, then measurement capability is improved, but device complexity increases due to image processing requirements
Solution Approach 1:
The patent makes the image processing system multi-functional to justify the complexity investment. The same image capture and processing infrastructure serves multiple purposes: determining tool presence in storage locations, identifying specific tool types through image analysis, generating inventory reports, providing visual documentation for audits, and enabling various inventory management functions. This universality spreads the complexity cost across multiple valuable capabilities.
Data Source
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AI summary
An inventory control system and method determines an inventory condition of objects stored in the system. Embodiments include a storage container including a plurality of storage locations for storing objects; an image sensing device to capture image data of the container, including image data of the plurality of storage locations and a target area that includes an individual object storage location having less than the plurality of storage locations; a data storage device for storing the image data of the container; and a data processor. The processor receives initial image data representing an initial image of the plurality of storage locations, and image data representing an image of the target area captured subsequent to the initial image; modifies the initial image data based on the image data of the target area to generate adjusted image data; and stores the adjusted image data in the data storage device.