# US 10,372,117 B2 · Systems and methods for assuring and improving process quality > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,372,117 B2 - Document ID: US10372117B2 - Status: Granted - Kind: B2 - Application number: 14/905,105 - Filed: 2013-07-18 - Published: 2016-05-19 - Granted: 2019-08-06 - Earliest claimed: 2013-07-18 - Assignees: Toyota Motor Europe; Toyota Jidosha Kabushiki Kaisha - Applicants: Toyota Motor Europe NV/SA; Toyota Jidosha Kabushiki Kaisha - Inventors: Andrew Willett; Tomoya Okazaki; Shingo Iwatani - Web page: https://patentgrep.com/patent/US10372117B2 ## CPC - G05B 19/41875: {characterised by quality surveillance of production} - B23K 26/032: {using optical means} - B23K 26/282: of tube sections - B23K 31/125: {Weld quality monitoring} - G06T 7/0004: {Industrial image inspection} - B23K 2101/06: Tubes - G05B 2219/32179: Quality control, monitor production tool with multiple sensors - G06T 2207/30152: Solder - Y02P 90/02: Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS] - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - G06T: IMAGE DATA PROCESSING OR GENERATION, IN GENERAL - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A system for evaluating at least one state of a process is provided the system having means for segmenting the process into a plurality of process segments, one or more sensors configured to capture information related to each process segment of the plurality of process segments generated by the segmenting means, the information comprising a plurality of samples, and processing means configured to process the plurality of samples related to each process segment of the plurality of segments, and, based on the processing, provide an indication associated with the at least one state of the process. ## Claims ### Claim 1 A method for evaluating at least one state of an assembly process of a work piece, comprising: segmenting the assembly process on a spatial basis into a plurality of process segments; capturing information related to each process segment of the plurality of process segments, the information comprising a plurality of samples captured during the assembly process at a predetermined temporal frequency; processing the plurality of samples related to each segment of the plurality of process segments such that numerical data associated with each sample is generated; performing a statistical analysis on the numerical data to generate a plurality of process values wherein each process value is associated with one of the samples; determining whether the process values exceed a threshold value; determining one or more physical defects in the work piece as a result of the assembly process when one or more process values exceeds a threshold value; and in response to a determination that one or more of the plurality of process values exceeds the threshold, labelling the work piece for disposal as having failed the assembly process, based on the one or more physical defects determined. ### Claim 2 (depends on 1) The method according to claim 1, further comprising sub-segmenting each of the plurality of process segments into a plurality of sub-segments. ### Claim 3 (depends on 1) The method according to claim 1, further comprising, specifying a set of parameters defining at least one of the plurality of segments, the samples, and the process. ### Claim 4 (depends on 1) The method according to claim 1, wherein the processing comprises applying one or more algorithms to the plurality of samples to result in data points. ### Claim 5 (depends on 4) The method according to claim 4, wherein the one or more algorithms are selected from at least one of a maximum determining algorithm, a minimum determining algorithm, an average determining algorithm, a slope determining algorithm, an integral algorithm, a summing algorithm, logic actions, masking functions, local thresholding, global thresholding, adaptive thresholding, inversing the image, filling parts of the image, opening parts of the image, and noise spot removal. ### Claim 6 (depends on 1) The method according to claim 1, wherein a number of segments comprising the plurality of segments is configured based on the process being analyzed. ### Claim 7 (depends on 1) The method according to claim 1, further comprising a user configuration step, wherein a user may configure at least one of the number of segments and a statistical state associated with a physical defect. ### Claim 8 (depends on 1) The method according to claim 1, wherein the process includes at least one of assembly process, a composite curing process, a composite consolidating process, a powder cladding process, a powder spray process, a spray process, a brazing process, a composite tape laying process, a composite comingled fibre placement process, a heating and drying process. ### Claim 9 (depends on 1) The method according to claim 1, wherein the process is a welding process. ### Claim 10 A system for evaluating at least one state of an assembly process of a work piece, the system comprising: a processor configured to segment the assembly process on a spatial basis into a plurality of process segments; one or more sensors configured to capture information related to each process segment of the plurality of process segments generated by the processor, the information comprising a plurality of samples captured during the assembly process at a predetermined temporal frequency; wherein the processor is further configured to: process the plurality of samples related to each process segment of the plurality of segments such that numerical data associated with each sample is generated, perform a statistical analysis on the numerical data to generate a plurality of process values wherein each process value is associated with one of the samples, determine whether the process values exceed a threshold value; determining one or more physical defects in the work piece as a result of the assembly process when one or more process values exceeds a threshold value; and in response to a determination that one or more of the plurality of process values exceeds the threshold, label the work piece for disposal as having failed the assembly process, based on the one or more physical defects determined. ### Claim 11 (depends on 10) The system according claim 10, wherein output associated with the processing of each sample of the plurality of samples comprises a single numeric value. ### Claim 12 (depends on 11) The system according to claim 11, wherein an output associated with the processing of each segment of the plurality of process segments is a function of the single numeric value. ### Claim 13 (depends on 10) The system according to claim 10, further comprising a database comprising anomaly data associated with one or more predetermined anomalies. ### Claim 14 (depends on 10) The system according to claim 10, wherein the one or more sensors comprises a camera and/or a microphone configured to capture radiation data. ### Claim 15 (depends on 10) The system according to claim 10, wherein the plurality of samples comprise at least one of an image and a sound. ### Claim 16 (depends on 10) The system according to claim 10, further comprising a band pass filter configured to selectively transmit radiation data within a predetermined wavelength or group of wavelengths and to prevent transmission of radiation data outside of the predetermined wavelength. ### Claim 17 (depends on 10) The system according to claim 10, further comprising a user interface, the user interface being configured to enable customization of a set of parameters defining at least one of the plurality of segments, the samples, and the process. ### Claim 18 (depends on 10) The system according to claim 10, wherein the one or more sensors is configured to capture images in three-dimensions. ### Claim 19 (depends on 13) The system according to claim 13, wherein the database further comprises comparative data related to the plurality of samples based on one or more algorithms. ### Claim 20 (depends on 10) The system according to claim 10, further comprising a storage device configured to store one or more of the plurality of samples captured during the process, and for outputting one or more of the plurality of samples in a format visible and/or audible to a human user. ### Claim 21 A system for evaluating at least one state of an assembly process of a work piece, the system comprising: a processor configured to segment the assembly process on a spatial basis into a plurality of process segments; one or more sensors configured to capture information related to each process segment of the plurality of process segments generated by the processor, the information comprising a plurality of samples captured during the assembly process at a predetermined temporal frequency, wherein a trigger between process start/stop and data capture start/stop initiates and synchronizes a position of the work piece and said process segments; wherein the processor is further configured to: process the plurality of samples related to each process segment of the plurality of segments such that numerical data associated with each sample is generated, perform a statistical analysis on the numerical data to generate a plurality of process values wherein each process value is associated with one of the samples, determine whether the process values exceed a threshold value; determining one or more physical defects in the work piece as a result of the assembly process when one or more process values exceeds a threshold value; and in response to a determination that one or more of the plurality of process values exceeds the threshold, label the work piece for disposal as having failed the assembly process, based on the one or more physical defects determined, wherein a position of a said one or more physical defects on said work piece is determined based on said synchronization of position and data capture.