Analysis Solution to Improve Fault Detection on Mechanical Assembly Production Lines

改善机械装配生产线故障检测的分析解决方案

• 批准号: 10073325
• 金额: $ 1.15万
• 依托单位: HELICAL TECHNOLOGY LTD.
• 依托单位国家: 英国
• 项目类别: Collaborative R&D
• 财政年份: 2023
• 资助国家: 英国
• 起止时间: 2023 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=10073325
• 关键词: Analysis; Solution; Improve; Fault; Detection

**Helical Technology Ltd****Generating an affordable, easily-trainable, vision fault-detection system for easy deployment across multiple product assembly lines.****Challenge**Helical Technology is a family-owned manufacturing business based in the North-West which from establishment over 50 years ago as a spring manufacturer, has grown into a global supplier of several specialised mechanical products including valve rotators, actuators and valves.Many production lines within Helical's two UK sites are required to produce a varied range of products in a given day, and many assembly processes rely on precise positioning of component parts to avoid faults and costly quality issues.Historically, quality was often assured by conducting a manual over-check of parts, which was both time consuming and prone to error. In some cases, commercially available vision systems had been deployed on lines to improve throughput and checking quality, but their use across the production line had been limited due to the inherent costs of purchasing and then reconfiguring such systems, which often required outsourcing to third parties.**Solution**Having noted recent advancements in the fields of machine learning an artificial intelligence, a Helical Engineer began to experiment with open-source codes to teach a machine algorithm detect a simplified build error. After gaining some initial successes, it was recognised that further external expertise and resource was needed to produce a full inspection system and develop this idea further.Helical Technology sought partnership with STFC Hartree Institute on an A4I funded project, which led to the development and supply of a novel easily-trainable analysis software method, and the production and deployment of the first demonstrator unit.**Impact**The deployment of the demonstrator system on a Helical production line immediately led to the elimination of the human visual checking operation, which saw increased line productivity and quality of output.Instead of being replaced by a machine, line operatives were redeployed onto more productive and less onerous tasks elsewhere.The demonstrator unit served as a pilot "Industry 4.0" project within the business and was well received by employees, prompting further similar projects to be birthed around the business.Through the collaborative A4I project, Helical employees involved were upskilled in empowered to re-calibrate the unit in house, start new projects, and advise others with their expertise.Through publicity of this project to the wider UK manufacturing community, other similar manufacturing SMEs were prompted to undertake similar projects to increase their competitiveness.

**Helical Technology Ltd****生成一个经济实惠、易于培训的视觉故障检测系统，以便在多个产品装配线上轻松部署。****挑战**Helical Technology 是一家家族制造企业，总部位于North-West 成立于 50 多年前，最初是一家弹簧制造商，现已发展成为阀门旋转器、执行器和阀门等多种专业机械产品的全球供应商。Helical 的两个英国工厂内有许多生产线，需要生产各种不同的弹簧产品。给定的产品许多装配过程都依赖于零部件的精确定位，以避免出现故障和代价高昂的质量问题。从历史上看，质量通常是通过对零件进行手动过度检查来保证的，这既耗时又容易出错。在某些情况下，商用视觉系统已部署在生产线上，以提高吞吐量和检查质量，但由于购买和重新配置此类系统的固有成本（通常需要外包给第三方），它们在生产线上的使用受到限制。 **解决方案**注意到机器学习和人工智能领域的最新进展后，一位螺旋工程师开始尝试使用开源代码来教授机器算法检测简化的构建错误。在取得一些初步成功后，人们认识到需要更多的外部专业知识和资源来生产完整的检测系统并进一步发展这一想法。Helical Technology 在 A4I 资助的项目上寻求与 STFC Hartree Institute 合作，从而促成了开发和供应一种新颖的、易于训练的分析软件方法的开发，以及第一个演示单元的生产和部署。**影响**演示系统在 Helical 生产线上的部署立即消除了人工目视检查操作，这看到增加生产线生产力和产出质量。生产线操作员没有被机器取代，而是被重新部署到其他地方，从事生产力更高、工作量更少的任务。演示单元作为企业内的“工业 4.0”试点项目，受到了员工的好评，促使更多类似的项目在企业周围诞生。通过协作 A4I 项目，参与的 Helical 员工获得了重新校准内部设备、启动新项目以及为其他人提供建议的技能。通过向更广泛的英国制造业界宣传该项目，促使其他类似的制造业中小企业开展类似的项目，以提高竞争力。