Basic Principles
Worker assistance system for real-time quality assurance of manual production processes
Poka Yoke - the nexonar Assembly Scout software enables error-free work in manual assembly and picking. Movements of tools or hands are analyzed in real time. The Scout assists and helps to avoid errors.
The system is configured by the simple programming of the manufacturing instructions and the associated assembly points at the workstation. Various interfaces are optionally available to link ERP and control points. One or more nexonar cameras can be positioned depending on workplace size and work flow. These are used for the acquisition of spatial coordinates and the orientation of nexonar infrared targets. Each of these targets can be captured with 6 degrees of freedom by a single camera.
With many cameras a wide variety work stations can be captured. Generally, 1-2 cameras are sufficient for an assembly station. After the start of the production process, which happens manually or through the control station software, the nominal positions of the respective manufacturing instructions are now compared to the actual positions of the hands, fingers, or, for example, the nut of a screwdriver. The measured object positions release an automatic confirmation of the successful completion of a target position and allow the continuation to the next step of the process.
Several different objects can be tracked simultaneously with 6 degrees of freedom in the measuring room
Example:
8 operators - each with a tracker on the left and right arm or 8 different tools
All can be identified at the same time, individually, in a work area. Even very fast movements can be captured without error, with high repeatability.
The IR tracker are attached to the objects that are to be measured (arms, hands, head or tools – such as a screwdriver).
1-32 cameras can be used to capture a wide variety of workplace sizes.
The Scout analyzes in real time and thus prevents errors with:
The Scout assists the operator with:
The flexible system offers many possibilities
An infinite number of combinations of manufacturing instruc- tions are quick and easy to produce.
The system can be easily retrofitted to jobs. The component boxes do not require complicated wiring. No additional sensors are needed to implement the quality standards.
Even without an ERP system and connection to a control network, the Assembly Scout is simple to use.
The 6DoF tracking has been developed specifically for applications in which objects or people need to be measured in small but also in larger environments. The IR technology offers the option of analyzing multiple objects at the same time in 3D space with up to 163 Hz in quasi real time. Up to 16 trackers can be captured with a single nexonar camera in a range of approx. 8.8 m x 4.8 m. A single nexonar IR single camera with wide angle covers a working area of 0.2 - 5.5 m depth. The standard Tracker sizes are small, medium and large. Housing forms and technical adjustments are feasible.
Precise measurement of movements in an area is easily made possible by IR technology – whether it‘s people, tools, machines or vehicles. The applied technology is simple, accurate and cost-effective when compared to existing technologies.
IR LED Camera Tracking - system configuration: Measuring range enlargement by clustering