Multi-Station Workpiece Measurement for Production Trend Tracking
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Solution Overview
Problem
Existing automated factory manufacturing systems face inefficiencies in production scheduling and inspection due to the constraint of inspecting workpieces in the same order as production, leading to inefficient use of production and inspection resources and inability to detect trends in dimension changes over time.
Innovation Solution
A method that records the production order and time of workpieces, allowing them to be measured at multiple inspection stations, analyzing the results to produce an output signal that assesses production machine performance, detects trends, and adjusts the production process, enabling flexible scheduling and efficient resource use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If workpieces are inspected in the same order as production at a single inspection station, then the production sequence is maintained for trend detection, but production scheduling efficiency deteriorates and inspection resources are underutilized
Solution Approach 1:
The inspection function is segmented across multiple inspection stations rather than concentrated at a single station. Each station inspects workpieces independently, allowing parallel processing of inspection tasks while maintaining sequence tracking through recording mechanisms. This segmentation enables flexible scheduling where different stations can handle different batches or types of workpieces simultaneously.
Solution Approach 2:
A recording mechanism serves as an intermediary between production and inspection processes. It records the production sequence and time of each workpiece, allowing the system to track trends without requiring sequential inspection. This intermediary decouples the inspection scheduling from the production sequence constraint, enabling efficient resource utilization while preserving trend analysis capability.
2Productivity
If inspection speed is increased to avoid slowing down production, then productivity improves, but measurement precision may deteriorate
Solution Approach 1:
The inspection workload is segmented across multiple stations, distributing the total inspection volume. Each station operates at optimized speed for its specific tasks, avoiding the need for any single station to operate at excessive speeds that would compromise accuracy. The parallel architecture maintains overall productivity while preserving measurement precision at each station.
3Measurement precision
If manual correction of production process is performed after inspecting workpieces in a quality control room, then analysis can be performed, but the beneficial effect does not reach workpieces produced in the meantime
Solution Approach 1:
The system implements automated feedback from inspection results to production machine control. Measurement data from multiple inspection stations is continuously monitored and automatically fed back to adjust production parameters in real-time. This closed-loop feedback eliminates the time delay of manual correction by automatically implementing process adjustments based on inspection findings, ensuring subsequent workpieces benefit immediately from corrections.
Solution Approach 2:
The system performs preliminary analysis of measurement trends continuously as data accumulates from multiple stations. Rather than waiting for batch analysis in a quality control room, the system proactively identifies trends and initiates corrective actions before defective workpieces are produced. This preliminary action prevents the time loss associated with delayed manual intervention.
Data Source
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AI summary
A workpiece production method is disclosed in which a plurality of nominally similar workpieces are produced in a production process on at least one production machine (e.g. 10). The order or time of production of at least some of the workpieces on the production machine (10) is recorded. At least some of the workpieces so recorded are measured at two or more inspection stations (20, 22, 24). Dimensions or points of one workpiece are measured at one of the inspection stations (20, 22, 24), and corresponding dimensions or points of another of the workpieces are measured at another of the inspection stations (20, 22, 24). The results of the measurements of corresponding dimensions or points made at the two or more inspection stations (20, 22, 24) are analysed together, taking account of the order or time of production of the workpieces. An output signal is produced based on the analysing of the results together. The output signal indicates performance of the production machine (10) or of one or more of the inspection stations (20, 22, 24).