Fraunhofer Institute scientists have developed quality control software that allows users without expert AI knowledge to benefit from AI.

Although they can bring great benefits in everyday work, many small and medium-sized enterprises (SMEs) shy away from applications based on artificial intelligence. But AI offers a lot of potential, especially in quality control. Nevertheless, training the models is difficult and hardly feasible without mathematical knowledge, as there are countless parameters that can go into such an analysis. And once an AI algorithm is learned, it is trained only on the specifications it learns. If a product design or the geometry of a component is later changed even slightly, the algorithm recognizes this as an error and the AI must be retrained.

Researchers at the Fraunhofer Institute for Digital Media Technology IDMT in Ilmenau, Germany, have now developed the “IDMT-ISAAC” software, which can be operated even without extensive expert AI knowledge. IDMT-ISAAC stands for Industrial Sound Analysis for Automated Quality Control. “We want to enable SMEs to adapt and customize AI algorithms themselves,” says Judith Liebetrau, group leader of Industrial Media Applications at Fraunhofer IDMT. “They can apply IDMT-ISAAC to their own audio data, retrain it, and thus get fast and reliable results and decision support for their quality assurance.”

Using AI even without expert knowledge

IDMT-ISAAC relies on acoustics for analysis, since in many cases it is possible to detect defects just by the sound of the process. To train the AI, the scientists use recorded acoustic data from welding processes. The AI analyzes the typical noises that occur and draws conclusions about the quality of the respective weld seam from the audio data. If, for example, the geometry of a product is then changed, the user can teach this to IDMT-ISAAC with just a few clicks. As early as summer 2021, the software should be adapted to live operation to the extent that the system can immediately analyze real-time data from production and optimize quality assurance. In three to four years, it should even be able to actively intervene in production.

But the framework at the heart of IDMT-ISAAC doesn’t offer new analysis options just for welding. “We have integrated various methods in the modular system to be able to map other processes, such as milling, relatively quickly,” Liebetrau explains. Companies that already have their own software should also be able to use it in the future. They will also be able to access the institute’s AI via an interface on the Fraunhofer IDMT server. It is important to the developers here to emphasize that data protection and data security would always be observed and that the data would be processed anonymously, regardless of whether companies access the AI via an interface or it is integrated into the company via the framework.

Making AI comprehensible

For different user groups – AI novices as well as AI experts – the software can be customized via different user profiles. For example, developers of AI algorithms are very interested in getting a feel for how AI makes its decisions and the sounds it uses to make them, says Judith Liebetrau. “So we are also moving a bit in the direction of Explainable AI with the framework to make AI more comprehensible,” Liebetrau says.

The researchers will present IDMT-ISAAC at the Hannover Messe from April 12 to 16, 2021. At the virtual booth, Bescher will apply artificial intelligence models using the IDMT-ISAAC software to industrial audio data to verify its quality.

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Rethink, now part of the Hahn Group, says the ASM setup was simple and the operation enabled Sawyer to “quickly achieve high levels of acceptance among employees”.

The task of the SMT Solutions business segment in the ASM Pacific Technology group is to support, implement and realize the SMT Smart Factory for electronics manufacturers worldwide.

ASM solutions such as the SIPLACE Placement Systems and the DEK Printing Solutions support the networking, optimization and automation of central workflows at the line and factory level with hardware, software and services and allow electronics manufacturers the gradual transition to the Smart SMT Factory with dramatic improvements in key figures / KPIs for productivity, flexibility and quality.

The central strategy element at ASM is the close cooperation with customers and partners. ASM initiated the SMT Smart Network as a global competence network for the active exchange of experiences between Smart Champions.

ASM is a co-founder of the ADAMOS joint venture to develop an IIoT platform for manufacturing companies and, together with other SMT manufacturers, is establishing the open standard HERMES as SMEMA successor for M2M communication in SMT lines.

The task

ASM uses Rethink Robotics’ cobot Sawyer in quality control. Sawyer independently performs the checks by picking up a part from the existing assembly, performing a scan of the surface and placing the board in a test adapter.

After this OK / NOK test, Sawyer separates the parts based on the results and releases them for further processing. Defective parts are removed from the process chain and deposited by Sawyer in a special area so that they can be transferred to the fault analysis.

Another challenge initially was the employees’ acceptance of the cobot. Manufacturing workers feared that Sawyer would be a machine that could endanger their jobs in the long term.

However, this idea changed quickly because Sawyer takes on repetitive tasks, which means that ASM employees can apply their skills for more demanding tasks in the value chain.

After a brief familiarization, the cobot has become part of the team in production, which gave him the new nickname “Paul”.

Project progress

The ASM decision-makers got to know a Sawyer application, which offered an opportunity to automate the previously manually performed quality control of printed circuit boards. Sawyer was able to pick up parts independently and use them in a test system.

During the first meeting for the live demo of Rethink Robotics, the ASM decision-makers were impressed by how easy it is to program Sawyer through the Intera software.

Advantages for the customer

Alessandro Bonara, head of electronic manufacturing at ASM Assembly Systems, says: “It was very impressive for us that the Sawyer is so quick and easy to assemble.”

After delivery, assembly and connection, Sawyer is immediately ready for use. In comparison to conventional industrial robots, Sawyer is much easier to set up and put into operation.

Another bonus is that Sawyer does not have to be fixed to the floor of the assembly hall with screws, which makes its mobility another huge advantage in terms of flexibility.

Programming the Intera software is very easy for the user due to its structure and operation.

Employees can either build the program modularly using “Teach by Demonstration”, which works by moving the robot arm in the room, or using landmarks to specify a framework that Sawyer can use to learn how to perform his movements.

As a final step, an employee can fine-tune the programmed movements using the Intera software.

The safety aspect in the cooperation between humans and collaborative robots has the highest priority when using Sawyer.

That is why cobot Sawyer continuously controls his use of force, the position of his robot arm and has a collision control. The entire application used in production at ASM is CE certified.

Productivity and quality improvements

The cooperation between Rethink Robotics and ASM was “very constructive and reliable”, say the companies.

For ASM, productivity and quality improvements are among the most important goals.

The use of technologies for automation is an important step, which is why the automated quality control with cobot Sawyer fits well into the ASM manufacturing process.

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NEW DELHI: The Ministry of Statistics and Programme Implementation said on Monday it is proposing to establish a National Data Warehouse on Official Statistics which will leverage technology and use big data analytical tools to improve the quality of macro-economic aggregates.

As all these reforms are an ongoing process, it is important that the readers and users understand and appreciate the limitations of data and the challenges in estimation, said the ministry.

While undertaking these reforms, it is important to realise that newer data sets and survey results will invariably be used and it would be incorrect to comment that old processes were better than the new, it said.

“The reforms being undertaken in the ministry will lead to better data sets and better estimates in future. This will be duly deliberated on by the Advisory Committee on National Accounts Statistics (ACNAS) during the base year revision,” the ministry said in a statement.

Several economic commentators continue to raise questions on India’s GDP numbers and the official statistical machinery.

“The national statistical system works in an ecosystem of independence and autonomy in its statistical processes. Allusions to any external influence are altogether unwarranted,” said the statement.

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