Method for Inspecting a Correct Execution of a Processing Step of Components, in Particular a Wiring Harness, Data Structure and System

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a method and system for optical inspection of components, especially wiring harnesses, during their assembly process. It dynamically uses machine-readable markers (such as barcodes or data matrix codes) on both components and locations to not only identify what each part is and where it is, but also to check if the components are correctly placed and assembled at each production step. The system automatically detects and evaluates if the correct components are in the right locations, based on real-time images and predefined rules, making the inspection more reliable and less susceptible to human error and product variability.

Use CasesContent extracted from patent full text and abstract with AI.

• Automated quality inspection in automotive wiring harness manufacturing lines.
• Assembly verification in other industries with complex, manual or semi-automated assembly processes (e.g., aerospace, electronics, appliances).
• Real-time error detection and guided rework in manual assembly stations.
• Inspection and validation in the manufacturing of safety-critical electrical systems.
• Inventory control and process traceability in factories using barcoded/data matrix coded components.
• Robotic or augmented-reality guided assembly processes in smart factories.

BenefitsContent extracted from patent full text and abstract with AI.

• Reduces dependency on costly, complex, or rigid machine vision systems or robot-mounted cameras.
• Enables flexible, automated, and reliable inspection even with high product and process variability.
• Allows for immediate detection and correction of assembly errors, reducing costly end-of-line rework.
• Usable with low-cost industrial cameras and simple hardware, lowering inspection system costs.
• Easily adapts to changes in components or process steps without the need for lengthy re-training of image recognition models.
• Improves traceability and process transparency by tying component and location identities to process data.
• Enhances inspection of partially hidden or look-alike components via markers, overcoming limitations of traditional visual features.

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Patent Abstract

The described method as a key enabler for Optical Inspection dynamically uses individual marks like fiducials, barcodes, data matrix codes ("markers") in the scenes, beyond their basic presence, meaning the change of situation between a first processing status and a subsequent processing status in the processing station. The same markers are simultaneously used for a) the identification of components ("comp") b) the identification of locations ("loc") and c) the definition of dependencies between identity and location (valid, invalid) and d) the automated detection and evaluation of the dependencies.