Wearable Projector for Manufacturing Workflow Automation
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Solution Overview
Problem
In manufacturing sites, the inefficiency in recognizing operator movements and maintaining manufacturing apparatuses leads to increased operation suspension times and decreased production volumes, as operators rely on paper checklists and manual reporting, which are cumbersome and disrupt production.
Innovation Solution
A wearable device with a projector, camera, and sensors that detect user movements and apparatus states, transmitting data to a server for real-time workflow display and automatic checklist management, allowing for accurate and efficient recognition of operator actions and apparatus maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operators use paper checklists for maintenance and manual reporting, then they can ensure completion of work steps, but the operation suspension time increases and production volume decreases
Solution Approach 1:
The patent replaces the mechanical paper checklist system with an electronic checklist system displayed on a head-mounted display. The electronic checklist is automatically updated based on sensor data from the manufacturing apparatus, eliminating the need for manual paper checking and reporting while ensuring work completion through automated tracking.
Solution Approach 2:
The system enables self-service by automatically detecting apparatus states through sensors and generating checklist items without operator intervention. The head-mounted display automatically updates checklist completion status based on detected states, allowing the system to manage its own maintenance tracking without requiring operators to manually fill out papers.
2Loss of information
If operators stop work to fill in paper checklists at each work step, then they can track maintenance progress, but the operation suspension time increases
Solution Approach 1:
The patent enables continuous maintenance tracking by displaying the checklist on the head-mounted display that operators can view without stopping work. The electronic checklist updates in real-time based on sensor data, allowing operators to continuously monitor and complete maintenance tasks without interrupting the work flow for paper recording.
Solution Approach 2:
The head-mounted display acts as an intermediary between the sensors detecting apparatus states and the operator. It automatically translates sensor data into checklist items and updates completion status, eliminating the need for operators to manually transfer information to paper checklists and reducing time loss.
3Loss of information
If operators manually write reports after returning to office, then they can document work completed, but the process becomes cumbersome and time-consuming
Solution Approach 1:
The patent replaces the manual paper report-writing process with an automated electronic reporting system. Sensors continuously detect apparatus states and automatically generate maintenance records, which are stored and transmitted electronically, eliminating the need for operators to manually write reports in the office.
Solution Approach 2:
The system performs self-service by automatically documenting all maintenance work through sensor data collection and electronic record generation. The apparatus itself provides the documentation data, and the system automatically compiles and stores the reports without requiring operator time and effort.
4Device complexity
If simple pattern match between images is used for operator recognition, then the processing is simple, but the recognition accuracy is low
Solution Approach 1:
The patent segments the image recognition process into multiple stages: first capturing images with the head-mounted camera, then extracting specific feature quantities (such as operator identity features, posture features) from the images, and finally comparing these extracted features with reference data. This segmentation allows accurate recognition while keeping each processing step manageable.
Solution Approach 2:
The system creates reference copies of operator features in advance and stores them for comparison. Instead of performing complex real-time analysis, the system captures current operator features, compares them against pre-stored reference copies, and identifies operators based on this comparison, simplifying the processing while maintaining accuracy.
Data Source
AI summary
According to one embodiment, a system includes a wearable device configured to be attached to a display configured to display a display image. The wearable device features an optical component set featuring a lens, a first user operable member configured to set an adjustment value relating to a projection angle of the visual image, and a second user operable member configured to set an adjustment value relating to at least one of a color tone or a brightness of the visual image. A position of the visual image is changed by adjusting the projection angle of the visual image using the first user operable member so that the visual image is displayed at a position based on at least one of a shape or a size of the head of the user. The color tone or the brightness of the visual image is changed using the second user operable member.