Voice Coil Winding Quality Control With Machine Vision Feedback
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Solution Overview
Problem
Conventional real-time voice-coil quality control processes in manufacturing rely heavily on manual experience and are inefficient, leading to uncontrollable production and reduced throughput due to the absence of quantitative data for machine adjustments.
Innovation Solution
A voice coil winding real-time quality control method that builds a qualitative influence model to correlate parameter input factors with quality inspection results, using machine vision inspection and self-taught machine learning to adjust parameters remotely and improve production line stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual quality control by technicians is used, then quality inspection can be performed, but production line throughput decreases and work efficiency is reduced
Solution Approach 1:
The patent replaces manual mechanical inspection by technicians with an automated machine vision inspection system that captures images of voice coils and uses algorithms to automatically detect defects, thereby eliminating the need for manual quality control while maintaining or improving inspection reliability
Solution Approach 2:
The inspection system performs self-diagnosis and quality assessment by automatically analyzing captured images against predefined quality standards, enabling the system to control its own quality evaluation without human intervention, thus freeing up production line workers
2Ease of operation
If trial-and-error commissioning is used, then parameter adjustment can be performed, but time is lost and productivity is reduced
Solution Approach 1:
The system implements real-time feedback by continuously monitoring quality parameters during production and automatically adjusting commissioning parameters based on detected deviations, eliminating the need for time-consuming trial-and-error commissioning while maintaining optimal operation
Solution Approach 2:
The system performs preliminary quality assessment and parameter optimization before full production begins by analyzing sample data and pre-adjusting commissioning parameters, thereby reducing the time needed for on-line trial-and-error adjustments during actual production
3Stability of the object's composition
If manual inspection is performed continuously, then quality stability can be maintained, but labor costs increase and work efficiency decreases
Solution Approach 1:
The patent replaces continuous manual inspection with an automated optical inspection system that uses cameras and image processing algorithms to monitor quality stability 24/7 without human intervention, thereby maintaining quality consistency while eliminating the need for continuous manual labor
Solution Approach 2:
The automated inspection system enables continuous uninterrupted quality monitoring throughout the entire production process without the breaks, fatigue, and human limitations inherent in manual inspection, thereby maintaining quality stability while maximizing work efficiency and production output
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
The method enhances production line throughput stability, improves yield rate, and increases work efficiency by reducing trial-and-error overheads and enabling remote, targeted parameter adjustments.
Implementation Method 1
inspecting, in real-time, a voice coil manufactured in the voice coil winding process via machine vision inspection
Data Source
AI summary
Disclosed is a manufacturing process optimization method, and more particularly relates to a voice coil winding real-time quality control method, system, and a corresponding apparatus. In the method as disclosed, the influence model is built via data analysis to calibrate relevancy between product quality and production line-related performance input parameter, which allows for directing a commissioning technician to perform remote, targeted parameter adjustment, without constant trial and error on the production line or shutting down the production line for adjustment like in conventional technologies; the method disclosed herein enhances production line throughput stability and can effectively improve the yield rate and work efficiency of the voice coil production line.