Smart Assembly Quality Control – AI-supported quality control and worker guidance

In general, manual assembly processes start with the identification of the screw case at the assembly piece. Based on the recognition, the correct process parameters have to be selected to ensure a safe and high-quality screwing. The data, e.g. in form of screw curves has to be documented and saved in a quality management system. The results of the project “Smart Assembly Quality Control” support the worker in all the steps of the process. A “smart” Tool recognizes via a built-in camera the correct screw case, a AI in the background, based on a machine learning algorithm classifies it and the matching parameters are sent to the torque tool.

Assembly data of completed process steps are then reported back and saved for each individual and specific screw case. On a dashboard, the worker gets a visual feedback over the successful completion of the screwing process. This way, security-relevant and critical parts can be assembled in a process realiable way and the results are documented for future tracking.

Spring descriptiom

Based on the results of the sprint Smart Assembly Station ,we were looking for a solution for screw casese that are very close to each other. As a demonstration piece, the back plate of a washing mashine with in total ten different screws was used.

On the torque driver, a Raspberry Pi with a camera was mounted that automatically takes a picture when the tool is closer to 15 centimetres to the washing machine screw case. An AI that was specifically trained for this project and that is running on an edge device analyzes the picture and recognizes the correct screw case.

The torque tool then receives the right torque and after completion feeds back the exact process parameters that serve as input for a quality management system.

The worker is not limited to a predefined working order, instead he can proceed the assembly in a very natural way and in the order he chooses. Information about all completed assembly steps are visualized in a clear and simple dashboard. In case he sees an incorrect recognition, he can manually alter the results.

Smart Assembly Quality Control automates the way a qualified worker does his job, i.e. recognizing the current joint and selecting the right parameters. Ths way, an unskilled worker can archieve the same work results as a skilled labourer does. The high skilled worker is now free for more productive tasks.

SAQC
Tool
Dashboard
SAQC
Member companies

Atlas-Copco-200x200
Bossard-200x200
capgemini-Invent-200x200
miele-200x200