Vehicle seat correction system and method of correcting a defect in a vehicle seat

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Solution Overview

Problem

Manual inspection and rectification of defects in vehicle seats result in inconsistent judgment standards, increased labor and production time, and limited data documentation, hindering process and product improvements.

Innovation Solution

An automated vehicle seat correction system that involves imaging the seat, applying localized boundaries to defect areas, translating these boundaries into a seat-specific map, selecting a correction path for an automated device, and using the device to correct the defects, thereby reducing manual intervention and improving data accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual inspection and rectification of defects is used, then flexibility in handling various defect types is maintained, but labor time and production costs increase significantly

Engineering Contradiction:
Improveflexibility in handling defectsVSAvoidproduction time
Core Design Contradiction:
Ease of operationVSProductivity

Solution Approach 1:

The system enables self-service by having the automated device independently identify, locate, and correct defects on the seat surface without human intervention. The imaging device captures defect data, the controller processes this data to determine correction parameters, and the automated device executes correction, creating a self-contained defect rectification system that eliminates manual labor while maintaining operational flexibility.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical inspection and rectification system with an automated system comprising imaging devices, controllers, and automated correction devices. The mechanical actions of visual inspection, defect localization, and manual rectification are substituted with automated imaging, data processing, and machine-executed correction, thereby reducing labor time while preserving the ability to handle various defect types through programmable control.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If manual inspection is used, then adaptability to different defect types is maintained, but inspection consistency and judgment accuracy deteriorate

Engineering Contradiction:
Improveadaptability to defect typesVSAvoidinspection consistency
Core Design Contradiction:
Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The system implements feedback by capturing defect data through imaging devices, processing this data through a controller to generate correction parameters, and using these parameters to guide automated correction. The feedback loop ensures that each defect is systematically identified, measured, and corrected according to standardized criteria, eliminating the inconsistency inherent in manual inspection while maintaining adaptability to various defect types through programmable recognition algorithms.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent applies parameter changes by transforming defect characteristics captured by imaging devices into standardized correction parameters through controller processing. This systematic transformation of defect parameters into correction parameters ensures consistent measurement and evaluation across different defect types, replacing subjective manual judgment with objective, repeatable parameter-based assessment that maintains adaptability through configurable parameter sets.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If manual rectification of wrinkles is performed, then immediate defect correction is achieved, but labor costs and production time increase

Engineering Contradiction:
Improvedefect correctionVSAvoidrectification time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The system achieves continuity of useful action by integrating defect identification, parameter determination, and correction execution into a continuous automated process. The imaging device continuously monitors the seat surface, the controller continuously processes defect data and generates correction parameters, and the automated device continuously executes corrections, eliminating the intermittent nature of manual inspection and rectification cycles, thereby reducing total rectification time while ensuring reliable defect correction.

Inventive Principle:
Principle #20Continuity of useful action

Solution Approach 2:

The patent applies preliminary action by having the imaging device capture defect data and the controller determine correction parameters before the actual correction is executed. This preliminary data collection and parameter determination phase allows the automated correction device to execute corrections efficiently without interruption, reducing overall rectification time while maintaining reliable correction outcomes through pre-planned correction strategies.

Inventive Principle:
Principle #10Preliminary action

4Productivity

If automated correction system is implemented, then labor costs and production time are reduced, but system complexity increases

Engineering Contradiction:
Improveproduction efficiencyVSAvoidsystem complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The system applies universality by designing the automated correction system to perform multiple functions: defect imaging, data processing, parameter determination, and correction execution, all within a single integrated system. This multi-functional approach consolidates what would otherwise require separate systems for each function, reducing overall system complexity while maintaining high productivity through coordinated operation of unified components that can handle various defect types through programmable control.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses an intermediary approach by introducing a controller as a mediator between the imaging device and the automated correction device. The controller processes defect data, determines correction parameters, and translates these parameters into actionable commands for the correction device. This intermediary layer simplifies the overall system architecture by providing a centralized intelligence hub that coordinates between sensing and actuation components, reducing the complexity of direct point-to-point connections while enabling sophisticated defect correction capabilities.

Inventive Principle:
Principle #24Intermediary (Mediator)

Data Source

PatentUS11724931B2Vehicle seat correction system and method of correcting a defect in a vehicle seat
Publication Date: 2023.08.15 LEAR CORP
  • US11724931B2 patent drawing
  • US11724931B2 patent drawing
  • US11724931B2 patent drawing

AI summary

An example method of correcting a defect in a seat comprises the steps of: (a) imaging a seat to obtain an image of the seat, a portion of the seat having a defect; (b) applying a localized boundary around the portion of the seat having the defect within the image of the seat; (c) translating the localized boundary into a seat specific map of a baseline model of the seat such that a portion of the baseline model of the seat that corresponds to the portion of the seat having the defect within the image of the seat is disposed within a translated localized boundary; (d) selecting a predetermined path for an automated device to correct the portion of the seat having the defect based on the portion of the baseline model of the seat; and (e) correcting the portion of the seat having the defect.