Resonance Inspection Using Vibrational Trends for Process Control
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Solution Overview
Problem
Current part production processes lack effective methods to monitor and control manufacturing defects and process variations using 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 data from parts, correlating response characteristics with process variables, allowing for real-time feedback and adjustments to improve process control and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional production monitoring methods are used, then production speed is maintained, but manufacturing precision and quality consistency deteriorate due to inability to detect process variations
Solution Approach 1:
The patent applies mechanical vibration through resonance inspection to detect process variations. Vibrational data is collected from parts during production and analyzed to identify trends indicating potential quality issues before they affect part compliance, enabling early process adjustments without slowing production.
Solution Approach 2:
The patent implements feedback by continuously monitoring vibrational characteristics and comparing them against established baselines. When deviations indicate process drift, the system provides feedback for process adjustment, maintaining quality consistency while allowing continuous production to proceed.
2Manufacturing precision
If resonance inspection is implemented for process control, then manufacturing precision improves through early detection of process variations, but device complexity increases due to additional monitoring equipment and data analysis systems
Solution Approach 1:
The patent makes the resonance inspection system multi-functional by using it for both individual part quality assessment and aggregate process control monitoring. The same vibrational data collection and analysis infrastructure serves dual purposes, reducing the need for separate systems and minimizing added complexity.
Solution Approach 2:
The system performs self-service by automatically collecting, analyzing, and interpreting vibrational data without requiring extensive external intervention. The automated trend detection and process variation identification reduce the need for manual inspection and complex external monitoring infrastructure.
3Loss of time
If vibrational data analysis is used for real-time process control, then loss of time is reduced by identifying issues before part non-compliance, but use of energy increases due to continuous data acquisition and processing
Solution Approach 1:
The patent applies partial action by monitoring only the specific vibrational frequency ranges and characteristics that are most indicative of process variations. Rather than analyzing the complete vibrational spectrum continuously, the system focuses on critical parameters, reducing processing energy while maintaining effective detection capability.
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 identification of trends and adjustments in process variables before parts become non-compliant, reducing defects and improving the overall consistency of the part production process by using vibrational data to monitor and control manufacturing processes.
Implementation Method 1
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.
Implementation Method 2
Resonance measurements may be made with electronic listening devices, contact transducers, laser interferometers, and other contact and non-contact means. Resonance data may be processed via fast Fourier Transforms (FFT), direct waveform measure, or other methods.
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.