Real-time quality control during manufacturing using augmented reality
Various techniques are described herein that provide for real-time quality control during manufacturing using augmented reality. In particular, in one embodiment, techniques herein project a three-dimensional (3D) virtual shape/model onto a work-in-progress part in the real-world in order to see defects in real-time, thus allowing for mid-manufacturing corrections. The embodiments herein generally consist of first calibrating a “virtual world” to the real world, then calibrating the physical product to the virtual world, and lastly projecting information onto the physical product, such as various design information and/or quality control information.
1. A method, comprising:
calibrating, by a process, a virtual world to a real world, the real world having one or more projectors and one or more sensors;
calibrating, by the process, a physical object in the real world to a virtual object in the virtual world based on the one or more sensors;
comparing, by the process, the physical object to the virtual object based on the one or more sensors;
determining, by the process, information about the physical object based on the comparing, wherein the information about the physical object comprises quality control information including an indication of one or both of either too little or too much material; and
projecting, by the process, the information about the physical object onto the physical object using the one or more projectors.
2. The method as in claim 1 , wherein the information about the physical object further comprises design information.
3. The method as in claim 1 , wherein the information about the physical object further comprises manufacturing instruction indications.
4. The method as in claim 1 , wherein the one or more sensors are selected from a group consisting of: infrared (IR) sensors; Light Distancing and Ranging (LIDAR) sensors; lasers; and cameras.
5. The method as in claim 1 , wherein the one or more sensors are locked into known positions in the real world.
6. The method as in claim 1 , wherein the one or more sensors are moveable in the real world, the method further comprising:
determining a position of each of the one or more sensors in the real world.
7. The method as in claim 6 , wherein determining the position comprises inside-out tracking.
8. The method as in claim 1 , wherein calibrating the virtual world to the real world comprises:
projecting a plurality of points, mapped within the virtual world, into the real world sensing positions of the projected plurality of points in the real world; and
correlating the sensed positions to the mapped points within the virtual world.
9. The method as in claim 8 , wherein one or more of the plurality of points are projected on one or more reference objects in the real world.
10. The method as in claim 8 , wherein one or more of the plurality of points are distinguishable from each other of the plurality of points.
11. The method as in claim 1 , wherein calibrating the physical object in the real world to the virtual object in the virtual world comprises:
performing an orientation technique to determine orientation, scale, and position of the physical object in relation to the virtual object according to the one or more sensors.
12. The method as in claim 1 , further comprising:
detecting that the physical object has moved within the real world; and
re-calibrating the physical object in the real world to the virtual object in the virtual world based on the one or more sensors.
13. The method as in claim 1 , wherein the one or more projectors are selected from a group consisting of: image projectors; headsets; tablets; phones; and smart glasses.
14. A method, comprising:
calibrating, by a process, a virtual world to a real world, the real world having one or more projectors and one or more sensors;
calibrating, by the process, a physical object in the real world to a virtual object in the virtual world based on the one or more sensors;
comparing, by the process, the physical object to the virtual object based on the one or more sensors;
determining, by the process, information about the physical object based on the comparing; and
projecting, by the process, the information about the physical object onto the physical object using the one or more projectors,
wherein the one or more sensors are selected from a group consisting of: infrared (IR) sensors; Light Distancing and Ranging (LIDAR) sensors; lasers; and cameras.
15. A method, comprising:
calibrating, by a process, a virtual world to a real world, the real world having one or more projectors and one or more sensors;
calibrating, by the process, a physical object in the real world to a virtual object in the virtual world based on the one or more sensors;
comparing, by the process, the physical object to the virtual object based on the one or more sensors;
determining, by the process, information about the physical object based on the comparing; and
projecting, by the process, the information about the physical object onto the physical object using the one or more projectors,
wherein the one or more sensors are locked into known positions in the real world.
16. A method, comprising:
calibrating, by a process, a virtual world to a real world, the real world having one or more projectors and one or more sensors;
calibrating, by the process, a physical object in the real world to a virtual object in the virtual world based on the one or more sensors;
comparing, by the process, the physical object to the virtual object based on the one or more sensors;
determining, by the process, information about the physical object based on the comparing; and
projecting, by the process, the information about the physical object onto the physical object using the one or more projectors,
wherein the one or more sensors are moveable in the real world, the method further comprising determining a position of each of the one or more sensors in the real world.
17. A method, comprising:
calibrating, by a process, a virtual world to a real world, the real world having one or more projectors and one or more sensors;
calibrating, by the process, a physical object in the real world to a virtual object in the virtual world based on the one or more sensors;
comparing, by the process, the physical object to the virtual object based on the one or more sensors;
determining, by the process, information about the physical object based on the comparing; and
projecting, by the process, the information about the physical object onto the physical object using the one or more projectors,
wherein calibrating the virtual world to the real world comprises:
projecting a plurality of points, mapped within the virtual world, into the real world sensing positions of the projected plurality of points in the real world; and
correlating the sensed positions to the mapped points within the virtual world.
18. A method, comprising:
calibrating, by a process, a virtual world to a real world, the real world having one or more projectors and one or more sensors;
calibrating, by the process, a physical object in the real world to a virtual object in the virtual world based on the one or more sensors;
comparing, by the process, the physical object to the virtual object based on the one or more sensors;
determining, by the process, information about the physical object based on the comparing; and
projecting, by the process, the information about the physical object onto the physical object using the one or more projectors,
wherein calibrating the physical object in the real world to the virtual object in the virtual world comprises performing an orientation technique to determine orientation, scale, and position of the physical object in relation to the virtual object according to the one or more sensors.
19. A method, comprising:
calibrating, by a process, a virtual world to a real world, the real world having one or more projectors and one or more sensors;
calibrating, by the process, a physical object in the real world to a virtual object in the virtual world based on the one or more sensors;
comparing, by the process, the physical object to the virtual object based on the one or more sensors;
determining, by the process, information about the physical object based on the comparing;
projecting, by the process, the information about the physical object onto the physical object using the one or more projectors;
detecting that the physical object has moved within the real world; and
re-calibrating the physical object in the real world to the virtual object in the virtual world based on the one or more sensors.
20. A method, comprising:
calibrating, by a process, a virtual world to a real world, the real world having one or more projectors and one or more sensors;
calibrating, by the process, a physical object in the real world to a virtual object in the virtual world based on the one or more sensors;
comparing, by the process, the physical object to the virtual object based on the one or more sensors;
determining, by the process, information about the physical object based on the comparing; and
projecting, by the process, the information about the physical object onto the physical object using the one or more projectors,
wherein the one or more projectors are selected from a group consisting of: image projectors; headsets; tablets; phones; and smart glasses.