VERIFICATION METHODS AND SYSTEMS FOR USE IN COMPUTER DIRECTED ASSEMBLY AND MANUFACTURE

• US 20130144416A1
• Filed: 06/06/2012
• Published: 06/06/2013
• Est. Priority Date: 06/06/2011
• Status: Active Grant

• Current Assignee: Paramit Corporation (Tecan Group AG)
• Original Assignee: Paramit Corporation (Tecan Group AG)
• Inventors: RATAUL, BALBIR S.
• Granted Patent: US 9,329,594 B2
• Time in Patent Office: Days
• US Class Current: 700/95
• CPC Class Codes: G05B 19/41805 characterised by assembly
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 19/4188 characterised by CIM planning or realisation
• CPC Class Codes: G05B 2219/24168 Identify connected programmer to allow control, program entry
• CPC Class Codes: G05B 2219/31001 CIM, total factory control
• CPC Class Codes: G05B 2219/31053 Planning, generate assembly plans
• CPC Class Codes: Y02P 80/40 Minimising material used in manufacturing processes
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Verification methods, systems, and computer program products verify the completion of assembly instructions used in light-manufacturing. Using position guides in a user interface, an in-use component is aligned and ready for verification through a first set of images of the in-use component. A visual highlight area on the user interface overlaying the in-use component indicates where to perform the assembly instructions. To create a traceable record, a second set of images are stored in an assembly record database when the assembler points a wand where the in-use component has been assembled. Another verification approach includes pointing an image capture device over the in-use component and receiving a first voice command authorizing image acquisition. A second voice command confirms accuracy of the image and proper assembly. Storing first and second voice commands and images of the in-use component being assembled in an assembly record database creates another traceable record useful for verification.

Claims

1. A computer-implemented method of verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, the method comprising:

displaying position guides in a user interface for aligning an in-use component being assembled in accordance with assembly instructions used on the in-use component associated with the manufactured product;

processing a first set of one or more images of the in-use component to determine when the in-use component has been positioned in a predetermined position relative to the position guides displayed by the user interface;

displaying an image of the in-use component being assembled with a visual highlight area on the user interface that overlays a portion of the in-use component where the assembler is to perform the assembly instructions and attach one or more materials, wherein the in-use component is in the predetermined position relative to the position guides;

processing a second set of one or more images of the in-use component being assembled to locate a tip of a wand being held by an assembler over a portion of the component that the assembler indicates has been worked upon; and

storing the second set of one or more images of the component being assembled in an assembly record database creating a traceable record of the materials used and the assembly operation performed.

2. The method of claim 1 wherein the assembler performs assembly instructions with the component placed on an assembly workstation.

3. The method of claim 1 wherein the assembler performs assembly instructions with the component located adjacent to the assembly workstation.

4. The method of claim 1 wherein the materials associated with the manufactured product are extracted directly from a Bill of Materials in an enterprise database system.

5. The method of claim 1 wherein the position guides appear on the user interface as a pair of cross-hairs positioned diagonally and separated by a distance corresponding to at least one dimension of the in-use component.

6. The method of claim 1 wherein the first set of one or more images are taken using an image capture device having a capture mode selected from a set including a single image mode and a video image mode.

7. The method of claim 1 wherein processing a second set of one or more images occurs upon receiving confirmation that the assembler has completed the assembly instructions associated with the operation as provided through the user interface.

8. The method of claim 1 further comprising associating a warning indicator with the second set of one or more images taken of the component being assembled indicating the component may have been assembled incorrectly, wherein processing of the second set of one or more images indicates that the assembler did not place the tip of the wand in a visual highlight area where operation was to be performed, and wherein the warning indicator is stored along with the second set of one or more images in the assembly record database.

9. A computer-implemented method of verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, the method comprising:

positioning an image capture device over a portion of an in-use component that received materials as a result of an assembler completing one or more assembly instructions displayed on a user interface;

processing a first voice command from the assembler authorizing acquisition of an image from the image capture device positioned over the portion of the in-use component;

processing a second voice command from the assembler confirming accuracy of the image acquired and that the in-use component has been properly assembled; and

storing the first and second voice commands from the assembler and images of the in-use component being assembled in an assembly record database creating a traceable record of the materials used, the assembly operation performed, and an assembler'"'"'s verbal participation.

10. The method of claim 9 wherein the assembler performs assembly instructions with the component placed on an assembly workstation.

11. The method of claim 9 wherein the assembler performs assembly instructions with the component located adjacent to the assembly workstation.

12. The method of claim 9 wherein the materials associated with the manufactured product are extracted directly from a Bill of Materials in an enterprise database system.

13. The method of claim 9 wherein processing a first voice command comprises:

displaying the image acquired on the user interface allowing the assembler to determine if the in-use component appears to have been assembled properly and if the image accurately captures the portion of in-use component.

14. The method of claim 9 wherein the first voice command includes the phrase, “

Take photo”

.

15. The method of claim 9 wherein the second voice command includes the phrase, “

Photo ok”

.

16. The method of claim 9 further comprising:

processing a third voice command resulting from requiring the assembler to read a predetermined confirmation statement presented on the user interface and storing the third voice command in the assembly record database with other voice commands, wherein a match between the third voice command and the predetermined confirmation statement provides an indicia of the assembler'"'"'s attention when assembling the manufactured product.

17. The method of claim 16 wherein the predetermined confirmation statement corresponds to at least one assembly instruction selected from the sequence of one or more assembly instructions.

18. The method of claim 16 wherein the predetermined confirmation statement is a randomly generated phrase.

19. The method of claim 9 further comprising:

displaying assembly instructions in the user interface for an in-use component being assembled and a predetermined image of a previously assembled component with a visual highlight area that overlays a portion of the previously assembled component to receive materials through the assembly instructions, wherein the assembly instructions relate the visual highlight area from the previously assembled component with the portion of the in-use component.

20. A computer program product for verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, tangibly stored on a computer readable medium, comprising instructions operable to cause a programmable processor to:

display position guides in a user interface for aligning an in-use component being assembled in accordance with assembly instructions used on the in-use component associated with the manufactured product;

process a first set of one or more images of the in-use component to determine when the in-use component has been positioned in a predetermined position relative to the position guides displayed by the user interface;

display an image of the in-use component being assembled with a visual highlight area on the user interface that overlays a portion of the in-use component where the assembler is to perform the assembly instructions and attach one or more materials, wherein the in-use component is in the predetermined position relative to the position guides;

process a second set of one or more images of the in-use component being assembled to locate a tip of a wand being held by an assembler over a portion of the component that the assembler indicates has been worked upon; and

store the second set of one or more images of the component being assembled in an assembly record database creating a traceable record of the materials used and the assembly operation performed.

21. The computer program product of claim 20 wherein the instructions that process the second set of one or more images occur upon receiving confirmation that the assembler has completed the assembly instructions associated with the operation as provided through the user interface.

22. The computer program product of claim 20 further comprising instructions, when executed, associate a warning indicator with the second set of one or more images taken of the component being assembled indicating the component may have been assembled incorrectly, wherein processing of the second set of one or more images indicates the assembler did not place the tip of the wand in a visual highlight area where operation was to be performed, and wherein the warning indicator is stored along with the second set of one or more images in the assembly record database.

23. An apparatus for verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, the apparatus comprising:

a processor capable of executing instructions; and

a memory holding instructions that when executed by the processor cause the processor to;

display position guides on a user interface for aligning an in-use component being assembled in accordance with assembly instructions used on the in-use component associated with the manufactured product;

process a first set of one or more images of the in-use component to determine when the in-use component has been positioned in a predetermined position relative to the position guides displayed by the user interface;

display an image of the in-use component being assembled with a visual highlight area on the user interface that overlays a portion of the in-use component where the assembler is to perform the assembly instructions and attach one or more materials, wherein the in-use component is in the predetermined position relative to the position guides;

process a second set of one or more images of the in-use component being assembled to locate a tip of a wand being held by an assembler over a portion of the in-use component that the assembler indicates has been worked upon; and

store the second set of one or more images of the in-use component being assembled in an assembly record database creating a traceable record of the materials used and the assembly operation performed.

24. The apparatus of claim 23 wherein the memory further comprises instructions, when executed, that associate a warning indicator with the second set of one or more images taken of the component being assembled indicating the component may have been assembled incorrectly, wherein processing of the second set of one or more images indicates that the assembler did not place the tip of the wand in the visual highlight area where operation was to be performed, and wherein the warning indicator is stored along with the second set of one or more images in the assembly record database.

25. A computer program product for verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, tangibly stored on a computer readable medium, comprising instructions operable to cause a programmable processor to:

position an image capture device over a portion of an in-use component that received materials as a result of an assembler completing one or more assembly instructions displayed on a user interface;

process a first voice command from the assembler authorizing acquisition of an image from the image capture device positioned over the portion of the in-use component;

process a second voice command from the assembler confirming accuracy of the image acquired and that the in-use component has been properly assembled; and

store the first and second voice commands from the assembler and images of the in-use component being assembled in an assembly record database creating a traceable record of the materials used, the assembly operation performed, and an assembler'"'"'s verbal participation.

26. The computer program product of claim 25, further comprising instructions, when executed, process a third voice command resulting from requiring the assembler to read a predetermined confirmation statement presented on the user interface and storing the third voice command in the assembly record database with other voice commands, wherein a match between the third voice command and the predetermined confirmation statement provides an indicia of the assembler'"'"'s attention when assembling the manufactured product.

27. An apparatus for verifying the completion of a sequence of one or more assembly instructions used when assembling a manufactured product, the apparatus comprising:

a processor capable of executing instructions; and

a memory holding instructions that when executed by the processor cause the processor to;

position an image capture device over a portion of an in-use component that received materials as a result of an assembler completing one or more assembly instructions displayed on a user interface;

process a first voice command from the assembler authorizing acquisition of an image from the image capture device positioned over the portion of the in-use component;

process a second voice command from the assembler confirming accuracy of the image acquired and that the in-use component has been properly assembled; and

store the first and second voice commands from the assembler and images of the in-use component being assembled in an assembly record database creating a traceable record of the materials used, the assembly operation performed, and an assembler'"'"'s verbal participation.

28. The apparatus of claim 27, further comprising instructions, when executed, that, process a third voice command resulting from requiring the assembler to read a predetermined confirmation statement presented on the user interface and storing the third voice command in the assembly record database with other voice commands, wherein a match between the third voice command and the predetermined confirmation statement provides an indicia of the assembler'"'"'s attention when assembling the manufactured product.