Apparatus, systems and methods for automating loudspeaker assembly

Abstract

This invention discloses a manufacturing system, apparatus, and method for loudspeakers and other manufactured articles, used to align loudspeaker components with a common centering reference for placement, regardless of feature dimensions. The loudspeaker motor assembly can be aligned based on a reference for the basket / washer assembly, wherein the remaining components are coupled, aligned, and adhered according to the same reference, thus improving concentricity, alignment, and orthogonality between components and apparatus. Loudspeaker suspension components can also be coupled using the same reference. Dedicated alignment mechanisms, such as centering chucks and mechanical grippers, can also be provided to align the placed and adhered loudspeaker components, and the adhesive can be mechanically controlled based on the aforementioned reference.

Description

[0001] This application is a divisional application of Chinese patent application No. 201680081371.4, filed on December 8, 2016, entitled "Apparatus, System and Method for Automated Speaker Assembly". Technical Field

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 264,733, filed December 8, 2015, entitled “APPARATUS, SYSTEM AND METHOD FORAUTOMATED SPEAKEER ASSEMBLY”, the entire contents of which are incorporated herein by reference.

[0003] This disclosure relates to the manufacturing and alignment of loudspeaker components or similar manufactured components. More specifically, this disclosure relates to providing a window of process parameters for the automated manufacturing of these components, and to sorting and aligning components to improve manufacturing and / or component (e.g., loudspeaker) performance. Background Technology

[0004] The vast majority of audio loudspeakers (“loudspeakers”) produced today are manufactured using at least partially automated manufacturing systems and processes. Typically, loudspeaker manufacturing centers on the yoke of the loudspeaker, assembling it by placing components on / around the yoke. Such a configuration can introduce one or more defects into the assembled loudspeaker, potentially causing a wide range of acoustic performance variations, mechanical alignment problems (such as friction and hum), and other quality issues arising from misalignment of loudspeaker components. This stems in part from the need for mechanical alignment techniques during manufacturing that account for the maximum tolerances of all components associated with the yoke, and to balance these physical alignment techniques with other alignment techniques, such as those previously described for aligning the voice coil with the magnetic field, i.e., adjusting the “DC offset” as needed. Of course, the increasing number of substantial and propagating defects during loudspeaker assembly can lead to significant yield reductions.

[0005] More specifically, current speaker assembly alignment techniques, which use alignment tools designed to support a wide range of tolerances, require gaps that cause misalignment of speaker components (including but not limited to speaker motor components). Misalignment can also introduce and / or amplify concentricity problems that can reduce speaker quality and performance, and make it more difficult to produce consistent acoustic products from multiple speakers manufactured over time or on the same production line.

[0006] The above situation is unacceptable because the industry, especially high-performance loudspeakers, is becoming increasingly refined. This means that loudspeaker performance needs to remain consistent across all loudspeakers of the same type (e.g., avoiding reduced stereo performance when using multiple loudspeakers) and throughout the long lifespan of each loudspeaker. Furthermore, due to variations in manufacturing tolerances, the integration of wireless loudspeakers with the acoustic system can lead to mismatches in loudspeaker performance, which is unacceptable.

[0007] The consistency of loudspeaker performance and the improvement of its lifespan are generally limited by the materials used in manufacturing and the aforementioned tolerances used in current manufacturing techniques. Moreover, the tolerances in current technology are essential to the main handcrafted characteristics of most current technologies. Therefore, improvements in the materials used in loudspeakers have a limited impact on the consistency of loudspeaker performance and its lifespan.

[0008] Therefore, there is a need for components and manufacturing processes and systems for manufacturing loudspeakers and similar articles, which improve the tolerances of manufactured articles and reduce the need for manual intervention in manufacturing, thereby improving performance consistency and lifespan. Summary of the Invention

[0009] The disclosed embodiments include loudspeaker assemblies and systems and methods for manufacturing loudspeaker assemblies and similar devices. Embodiments may include: firstly placing at least one upper washer on a centering fixture configured to secure and center the upper washer; actively and mechanically determining a base plane based on the center of the upper washer, wherein the base plane includes at least references for orthogonality and alignment; and after the determination, automatically placing and physically engaging one or more components, including at least one magnet and a loudspeaker yoke, on the upper washer, wherein each of the one or more components is aligned with the base plane; and wherein the yoke is operatively coupled to the magnet.

[0010] Accordingly, the disclosed embodiments provide a manufacturing system, apparatus, and method for manufactured articles such as loudspeakers, for aligning loudspeaker components with a common centering reference for placement, regardless of feature dimensions. The loudspeaker motor assembly can be aligned based on a reference for the basket / washer assembly, wherein the remaining components can be coupled, aligned, and adhered according to the same reference, thus improving concentricity, alignment, and orthogonality between components and apparatus. Loudspeaker suspension components can also be coupled using the same reference. Dedicated alignment mechanisms, such as centering chucks and mechanical grippers, can also be provided to align the loudspeaker components for placement and adhesion, and the adhesive can be mechanically controlled based on the aforementioned reference.

[0011] Therefore, the disclosed embodiments provide components and manufacturing processes and systems for manufacturing loudspeakers and similar articles, which improve the tolerances of the manufactured articles and reduce the need for manual intervention in manufacturing, thereby improving performance consistency and lifespan. Attached Figure Description

[0012] The invention will be more fully understood from the following detailed description and accompanying drawings, which are given by way of example only and therefore do not limit the scope of this disclosure, and wherein:

[0013] Figure 1 An exploded view of an exemplary speaker assembly suitable for automated production under the illustrative embodiment is shown;

[0014] Figure 2 An exploded view of an exemplary speaker assembly portion suitable for automated production under the illustrative embodiment is shown;

[0015] Figure 3 The process flow for assembling speaker components and sub-assemblies is shown in an illustrative embodiment;

[0016] Figure 3A The process flow for assembling speaker components and sub-assemblies related to a speaker motor is shown in an illustrative embodiment;

[0017] Figure 3B An illustrative embodiment is shown for use in Figure 3A The process flow shown is for assembling speaker components and sub-assemblies related to the speaker suspension after the process shown.

[0018] Figure 3C In the illustrative embodiments, it is used for assembly and Figure 3B The process flow for speaker components and sub-assemblies related to the speaker suspension shown continues;

[0019] Figure 3D-3H The process flow of one or more manufacturing units at different stages of the assembly process for motor assemblies and other components is shown in the illustrative embodiment.

[0020] Figure 4A The speaker assembly configuration on the tray is shown in an illustrative embodiment;

[0021] Figure 4B An illustrative embodiment is shown for use on a tray. Figure 4A The speaker assembly configuration shown is in which the gap shortening ring is placed and aligned on the upper washer;

[0022] Figure 4C An illustrative embodiment is shown for use on the upper gasket on the tray. Figure 4BThe speaker assembly configuration shown is with the lower washer placed and aligned on the gap shortening ring;

[0023] Figure 4D An illustrative embodiment is shown for use in Figure 4C The speaker assembly configuration shown, in which a lower shortening ring is placed and aligned on a lower washer, also includes a gap shortening ring on an upper washer on a tray;

[0024] Figure 4E An illustrative embodiment is shown for use in Figure 4D The speaker assembly configuration shown, in which the magnet is placed and aligned on the lower washer, also includes a gap-reducing ring on the upper washer coupled to the tray.

[0025] Figure 4F The illustration shows an example of a lower clearance shortening ring for use on a lower washer. Figure 4E The speaker assembly configuration shown, with the magnet placed and aligned with the yoke, also includes a gap-reducing ring on the upper washer on the tray;

[0026] Figure 5 A clamp configured for alignment and placement in a speaker assembly is shown in an illustrative embodiment;

[0027] Figures 6A-6C Different views of a clamp suitable for placement in a speaker assembly are shown in the illustrative embodiment;

[0028] Figure 7A An exemplary centering chuck configuration for aligning and placing components on a tray is shown in an illustrative embodiment;

[0029] Figure 7B An exemplary centering clamp chuck on a tray and an illustrative chuck component are shown in an exemplary embodiment;

[0030] Figure 7C An exemplary centering clamp chuck is shown, which is physically connected to a speaker assembly portion including an upper washer and a speaker basket, and is connected to a tray on a conveyor.

[0031] Figure 7D A perspective view is shown of an exemplary centering clamp chuck connected to a speaker assembly portion, which includes an upper washer and a speaker basket.

[0032] Figure 7E A side cross-sectional view is shown of an exemplary centering clamp head connected to a speaker assembly in an illustrative embodiment;

[0033] Figure 8An exemplary configuration (including a gap shortening ring) for aligning and placing a component onto a portion of a speaker assembly using a multi-finger gripper is shown in an illustrative embodiment.

[0034] Figures 9A-9B An exemplary component presentation device arrangement for presenting components in an illustrative embodiment is shown;

[0035] Figure 10A-15B The various concentricities measured for loudspeaker assembly components under various illustrative embodiments are shown;

[0036] Figure 16A Data showing the concentricity measurement results of the yoke to the upper washer under an illustrative embodiment are presented;

[0037] Figure 16B Data indicating the overall concentricity of the speaker assembly are shown in the illustrative embodiment;

[0038] Figure 17 Data indicating the centering repeatability of three-jaw and four-jaw chucks are shown in illustrative embodiments;

[0039] Figure 18A An alternative process for aligning components in a loudspeaker assembly is shown in an illustrative embodiment;

[0040] Figure 18B The illustration shows a method for preparing in an illustrative embodiment. Figure 19A The alternative process for placing and aligning magnets on the speaker assembly shown;

[0041] Figure 18C An illustrative embodiment is shown for use in Figure 19B The process of placing and aligning the lower washer and magnet on the speaker assembly shown;

[0042] Figure 18D An illustrative embodiment is shown for use in Figure 19C The process of placing and aligning the gap shortening ring on the speaker assembly shown;

[0043] Figure 18E An illustrative embodiment is shown for use in Figure 19C The process of placing and aligning the upper washer on the speaker assembly shown;

[0044] Figures 19A-19E An illustrative embodiment of the loudspeaker assembly process is shown, which utilizes a multi-unit manufacturing configuration to connect the basket / upper washer assembly to the gap shortening ring, lower washer, lower shortening ring, magnet, and yoke;

[0045] Figures 20A-20CAn illustrative embodiment of the loudspeaker assembly process is shown, which utilizes a multi-unit manufacturing configuration to connect the motor assembly with the voice coil, voice coil gauge, spider, cone / suspension, and dust cover; and

[0046] Figures 21A-21C Illustrative process steps performed at multiple units are shown, each unit being configured with the disclosed equipment / tools, as listed in a table, wherein... Figure 21A -B provides an illustrative unit-by-unit process for motor assemblies, while Figure 21B -C provides an illustrative unit-by-unit process for the suspension components;

[0047] Figure 21D Various aspects of the implementation methods are shown. Detailed Implementation

[0048] The accompanying drawings and descriptions provided herein have been simplified to illustrate aspects relevant to a clear understanding of the apparatuses, systems, and methods described herein, while other aspects that may be found in typical similar apparatuses, systems, and methods have been omitted for clarity. Those skilled in the art will therefore recognize that other elements and / or operations may be desirable and / or necessary for implementing the apparatuses, systems, and methods described herein. However, because such elements and operations are known in the art and because they are not conducive to a better understanding of this disclosure, a discussion of such elements and operations may not be provided herein. Nevertheless, this disclosure is to be considered to still include all such elements, variations, and modifications of the described aspects known to those skilled in the art.

[0049] Exemplary embodiments are provided throughout this invention to make the invention thorough and to fully convey the scope of the disclosed embodiments to those skilled in the art. Numerous specific details, such as examples of specific components, apparatuses, and methods, are set forth to provide a thorough understanding of embodiments of the invention. However, it will be apparent to those skilled in the art that certain specific details disclosed are not necessary, and that exemplary embodiments may be implemented in different forms. Thus, the disclosed exemplary embodiments should not be construed as limiting the scope of the invention. In some exemplary embodiments, well-known processes, well-known equipment structures, and well-known technologies may not be described in detail.

[0050] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless otherwise clearly stated herein, the singular forms “a,” “an,” and “the” should also include the plural forms. The terms “comprising,” “including,” and “having” are inclusive and thus specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, and / or combinations thereof. The steps, processes, and operations described herein should not be construed as necessarily interpreting their respective performance in the specific order discussed or shown, unless explicitly identified as a preferred performance order. It should also be understood that additional or alternative steps may be employed.

[0051] When a component or layer is referred to as “on,” “joined to,” “connected to,” or “coupled to” another component or layer, it may be directly on, joined to, connected to, or coupled to the other component or layer, or there may be intermediate components or layers. Conversely, if a component is stated as “directly on another component or layer,” “directly joined to another component or layer,” or “directly connected to another component or layer,” it indicates that there are no intermediate components or layers. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). The term “and / or” as used herein includes any and all combinations of one or more of the related listed items.

[0052] While the terms "first," "second," "third," etc., may be used herein to describe various elements, components, regions, layers, and / or portions, these elements, components, regions, layers, and / or portions should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or portion from another. Unless explicitly stated in the context, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence. Therefore, without departing from the teachings of exemplary embodiments, the first element, component, region, layer, or portion discussed below may be referred to as the second element, component, region, layer, or portion.

[0053] It should be understood that while the aspects discussed herein are illustrated by way of example relating to assembling a loudspeaker, they are applicable to a wide range of similar manufactured articles that can be improved by enhancing process automation, for example by improving the alignment and alignment tolerances of article components with respect to the central pathway. That is, many of the tools and steps disclosed herein can be used in other exemplary embodiments, such as for manufacturing other articles formed from other components, and therefore the discussion herein is provided by way of illustration only.

[0054] Furthermore, while the disclosed exemplary embodiments illustrate a speaker assembly process and system that is the reverse of known technologies, i.e., where assembly begins with the basket rather than the yoke, those skilled in the art will recognize that the examples provided below can be performed in two or more steps in a sequence similar to a typical speaker assembly process. More specifically, the disclosed order of certain steps detailed herein does not necessarily imply the necessary order for performing these disclosed process steps.

[0055] Now go to Figure 1 An exploded view of a simplified loudspeaker assembly 100 suitable for automated manufacturing under an illustrative embodiment is shown. Here, the loudspeaker assembly 100 includes a frame 110 (also referred to as a “bass” or “support”) that holds a washer 108, a magnet 106, and a rear plate 102 from the rear. The rear plate 102 has pole pieces 104 extending from the surface of the rear plate 102. In some illustrative embodiments, the rear plate 102 and the pole pieces 104 may be integrated as a “yoke,” which will be explained in further detail below. The loudspeaker assembly frame 110 may further hold one or more voice coils 112 from the front. The voice coils 112 include flexible wires / wire terminals 114 coupled to a flexible suspension (“spider”) 116 and a cone 118, which may include a suspension edge 120 and a dust cover 122. It is worth noting, and as further shown throughout the text, that without departing from the spirit or scope of this disclosure, additional shortening rings (such as larger shortening rings, gap shortening rings, etc.), washers, and other additional or fewer components may form an exemplary speaker according to the disclosed embodiments.

[0056] Figure 2 An exploded view of a speaker assembly portion 200 suitable for automated production, according to an illustrative embodiment, is shown. In this example, a frame 202 may be coupled to an upper washer 204, which is coupled to a lower washer 208 via a gap shortening ring 206. A yoke 214 may be coupled to a magnet 212 and to the lower washer 208 via a lower shortening ring 210. In some illustrative embodiments, the frame 202 may include a terminal 216.

[0057] During operation, when an electrical signal is applied to the voice coil (e.g., 112), a magnetic field is generated through the current in the voice coil, making it a variable electromagnet. This magnetic field, i.e., the "DC offset" of the loudspeaker, can be adjusted using the techniques, devices, and systems disclosed herein. The magnetic systems of the voice coil and the driver interact to generate mechanical forces that cause the voice coil 112 (and thus the attached cone) to move back and forth, thereby reproducing sound under the control of an applied electrical signal from the amplifier.

[0058] The cone 118 (or "diaphragm") can be manufactured in a conical or dome-shaped profile. A variety of different materials can be used, including but not limited to paper, plastic, and metal. In some illustrative embodiments, the cone material should be rigid to prevent uncontrolled cone movement; have low mass to minimize starting force requirements and energy storage issues; and be well-buffered to reduce continued vibration after the signal stops, resulting in little or no audible vibration due to the resonant frequency determined by its intended use. In some illustrative embodiments, the cone 118 can be made of some composite material. For example, the cone can be made of cellulose paper, in which some carbon fiber, Kevlar fiber, glass fiber, hemp fiber, or bamboo fiber may be added. In some illustrative embodiments, the cone 118 can be constructed of a honeycomb structure and / or a sandwich structure. In some illustrative embodiments, the cone 118 may include a coating to provide additional hardening or damping.

[0059] The frame (202, 110) can be configured as a rigid structure to minimize deformation that could alter the alignment with the magnetic gap, which in turn could cause friction on the sides of the voice coil 112. The frame (202, 110) can be cast from a metal such as an aluminum alloy or stamped from a metal such as a thin sheet of steel. In some illustrative embodiments, the frame (202, 110) can be configured as a cast metal, which can be advantageous when using a driver with a large magnet. Those skilled in the art will understand that other materials, such as molded plastics and damping plastic composites, can be used to form the frame (202, 110).

[0060] Suspension 116 can be configured to keep voice coil 112 centered in the gap and provide a restoring (centering) force that returns the cone to a neutral position after movement. In an illustrative embodiment, suspension 116 may include a spring 116 and a surround 120 that connects the diaphragm or voice coil to the frame (202, 110) and provides most of the restoring force. The surround 120 helps center the voice coil / cone assembly and allows free piston movement aligned with the magnetic gap. In an illustrative embodiment, spring 116 may include a corrugated fabric disc impregnated with a hardened resin. In other illustrative embodiments, a felt disc may be included to provide a barrier against particles that would otherwise cause friction against the voice coil. The cone surround 120 may be a rubber or polyester foam or a corrugated resin-coated fabric ring; it is attached to the circumference of the outer diaphragm and the frame. These different surround materials, their shapes, and treatments can be selected to affect the driver's sonic output.

[0061] The conductor 114 in the voice coil 112 can be configured as copper wire or any other suitable conductive material, such as aluminum. One advantage of aluminum wire is its light weight, which increases the resonant frequency of the voice coil 112 and allows it to respond more easily to higher frequencies. The cross-section of the voice coil conductor can also be used and can be configured as a circular, rectangular, or hexagonal structure, thus providing different numbers of conductor volumes covered in the magnetic gap space. In some illustrative embodiments, the voice coil 112 can be coaxially oriented within the gap to allow it to move back and forth within small circular volumes (holes, slots, or grooves) in the magnetic structure. The gap can be configured to establish a concentrated magnetic field between the two poles of the permanent magnet; one pole is on the outside of the gap, and the central post (or “pole plate” 104) is the other. The pole plate 104 and the back plate 102 can be configured as a monolith or a yoke (214). The magnets (212, 108) can be configured as permanent magnets formed of materials including, but not limited to, ferrite, AlNiCo alloys, or rare earth materials (e.g., neodymium and samarium cobalt).

[0062] Figure 3 The process flow for assembling speaker components and sub-assemblies is shown in an illustrative embodiment. Figure 3 The process flow can be performed on an automated or semi-automated assembly line, which will be discussed in further detail below. In block 302, a tray (e.g., 202) can be placed on a pallet (e.g., 404) and undergo a recorded relative pallet position, such as by any suitable technique.

[0063] As discussed throughout, alignment can include concentric and orthogonal alignment of components. Alignment can include active, passive, and / or redundant alignment of components and can be relative to a common reference point or reference point. For example, in an exemplary embodiment, a common reference, such as for a speaker motor assembly, can be a tray-residing centering clamp and / or one or more washers attached to the speaker "bass". As discussed, active mechanical centering can be used, and one or more centering devices can be employed. Furthermore, specific components such as the upper washer discussed herein can be used as alignment references, from which the speaker assembly is constructed "outward".

[0064] Additionally, the reference point or reference component may change as the disclosed exemplary design is executed. Through the examples above, a first reference component, such as the upper washer, can be used as a reference centering / alignment component until the different components (e.g., the yoke discussed herein) are positioned. Once positioned, this different component can serve as a reference component.

[0065] The disclosed alignment technique allows for component alignment tolerances smaller than 250 micrometers, and more specifically, for alignment tolerances in the range of 50-200 micrometers, for example, where alignment is performed in relation to an upper washer serving as a reference component. Thus, and by way of example only, component placement alignment can be performed based on placement data based on previously known positions of previously placed components, such as recorded positions of the upper washer and / or tray and / or recorded positions of previously placed components relative to the tray, and / or based on outputs of acquired position indication data, such as machine vision output, coordinate data of electronically readable position indicators or latch positions on the tray and / or components, etc.

[0066] Post-position alignment can include mechanical fingers, grippers, chucks, latches, etc., using inward or outward pressure, each of which can be tapered or non-tapered as discussed throughout this document. For example, such alignment tools can be spring-loaded, rack and pinion, or pneumatic.

[0067] Furthermore, whether explicitly stated or not, alignment can allow for variations in the process steps discussed herein. For example, based on known alignment data, the placement, patterning, quality, and repeatability of adhesives can be indicated and improved based on their relationship to the central axis of the component (e.g., alignment and / or concentricity). Similarly, the quality or distribution of adhesives can be indicated by at least alignment data and which components are placed next.

[0068] Now back Figure 3 Once the motor subassemblies are placed and aligned, adhesive can be applied to the frame, for example, to couple the spider to the frame. The voice coil and spider subassemblies can be placed at box 304 and aligned, for example, using a voice coil gauge. Next, adhesive can be applied to the voice coil to couple the spider to the voice coil (boxes 306 and 308). After adhesive application, the spider can be aligned and placed on the voice coil and frame in box 310, and after the spider is in place, adhesive can be applied around the spider / voice coil interface.

[0069] Once the adhesive has bonded or cured, wires and wire terminals (e.g., 114) can be installed and wired within block 312. Therefore, self-leveling and / or fast-curing adhesives can be used in exemplary embodiments, and uniformity, quality, concentricity, or similar factors can be controlled. In some illustrative embodiments, wires and terminals can be installed manually. In other illustrative embodiments, automated assembly equipment can be used to install wires and wire terminals.

[0070] Additionally, the suspension and cone can be placed and bonded before soldering the wires, as can the dust cover. This reordering can occur because, in some embodiments, the wire routing can be critical, and the quality and placement of the adhesive can be critical for providing a consistent, tolerant interface between the voice coil and spider, between the voice coil and cone, and between the dust cover and voice coil.

[0071] For example, in exemplary block 314, the spider can be further aligned and welded (e.g., using point-to-point (P2P) welding) to the voice coil and frame to secure the spider, wherein in block 316 adhesive is applied to the frame and used for the cone and suspension. In block 318, the cone and suspension can be aligned and placed on the frame relative to at least the frame and other attached components and / or relative to the tray 404 residing on the frame. In block 320 adhesive can be applied to the suspension for a dust cover, and in block 322 the dust cover can be aligned and placed on the voice coil.

[0072] Those skilled in the art should understand that, Figure 3 The processes described herein, as well as other processes and configurations described herein, are merely illustrative and not limiting. The type of adhesive used and any additives may depend on the assembly environment and may vary depending on the application. In one illustrative embodiment, the adhesive used may be a tacky, toughened, partial, room-temperature curing, instant adhesive designed for impact and peel strength in gap-filling OEM assembly applications (e.g., any suitable adhesive). In other illustrative embodiments, the adhesive may be an epoxy or a curable adhesive. In other illustrative embodiments, the adhesive may include an adhesion promoter (e.g., any suitable accelerator) to accelerate the adhesive curing process. As a non-limiting example, such an adhesion promoter may additionally include heating.

[0073] Go to Figure 3A , Figure 3A The process flow for assembling speaker components and sub-assemblies related to a speaker motor is illustrated in an illustrative embodiment. It should be noted that... Figure 3AIn the embodiments disclosed herein and other embodiments, for brevity, various processes may specify specific techniques for performing the process (e.g., manual, dispensing pin, vacuum gripper, three-finger clamp, etc.), but these specifications should not be construed as limiting, and those skilled in the art will readily recognize that other or additional techniques may be used to perform a particular process. In block 328, the basin rack may be glued and forged onto the upper washer. This step may be performed manually or using automated tools. The basin rack / upper washer assembly may then be picked up and placed onto a tray in block 329, where glue (i.e., adhesive) may be dispensed onto the upper washer (e.g., in a recessed shelf) for attachment to the gap shortening ring. In block 331, the gap shortening ring may be picked up and placed (e.g., using a multi-finger clamp) and coupled to the upper washer.

[0074] In order to couple the lower washer to the upper washer, an adhesive pattern can be applied to the upper washer in box 332 (e.g., all by a dispensing needle and / or controlled according to uniformity / quality / concentricity) to couple the lower washer, wherein the lower washer can then be picked up and placed in box 333 (e.g., by a vacuum clamp).

[0075] In box 334, the adhesive pattern can be applied to the lower washer (e.g., via a dispensing pin) and / or used to couple a magnet, wherein in box 335 the magnet can then be picked up and placed (e.g., via a vacuum gripper) and centered using a centering cone. In box 336, adhesive can also be applied to the lower washer (e.g., via a dispensing pin) to couple to a lower shortening ring, wherein the shortening ring can be picked up and placed (e.g., via a multi-finger gripper, such as a three-finger gripper) on the lower washer.

[0076] To attach the yoke assembly, the yoke can be picked up from a feeder (e.g., via a vacuum clamp) in block 338 and centered using a centering fixture (e.g., a deck tool) in block 339. In block 340, after adhesive has been dispensed onto the magnet, the yoke can be placed (e.g., via a vacuum clamp) onto the magnet for coupling.

[0077] In the illustrative embodiments, Figure 3A The process continues (“A”) to Figure 3BThe motor subassembly can be loaded into the suspension tray in block 342, and the voice coil gauge can be installed into the voice coil and loaded into the feeder tray in block 343. Furthermore, as a non-limiting example, the centering of the motor subassembly relative to the processing tray can be performed using the three-jaw gripper disclosed herein, including the assembly of the aforementioned suspension assembly. The processes shown in blocks 342 and 343 can be performed manually, or alternatively or additionally by automated machinery. In block 344, an automated machine, such as a robot, can place and center the speaker motor on the tray, with the motor locked in place. In block 345, the voice coil gauge can be picked up from the tray, and then in block 346, the voice coil gauge can be inserted into the voice coil. In box 347, the voice coil can be picked up (e.g., via a feeder) and placed (e.g., via a multi-finger gripper) into the spider to be fully in place, wherein in box 348, glue can be dispensed onto the spider (e.g., via a dispensing needle) to couple the spider to the frame.

[0078] In block 349, the voice coil gauge can be placed onto the yoke (e.g., via a multi-finger gripper), and then the spider can be positioned in block 350 (e.g., via a robot on the base plate). In block 351, after the voice coil is released (e.g., via a multi-finger gripper), in block 352, glue can be dispensed at the voice coil and spider interface (e.g., via a dispensing pin) to secure the coupling. In block 353, after the terminal wires are guided and an activator is applied, the cone can be picked up from the feeder in block 354 (e.g., via a vacuum gripper), and in block 355, glue can be dispensed (e.g., via a dispensing pin) onto the frame to couple with the cone. In block 356, the cone can be placed (e.g., via a vacuum gripper) onto the gauge to connect with the frame. In block 357, the position of the cone on the voice coil can be confirmed, for example, manually or automatically.

[0079] Figure 3B The process shown can continue (“B”) until Figure 3C In block 358, the cone is secured (e.g., by a vacuum clamp) to the glued frame surface. An activator can be applied in block 359, and the speaker can be removed from the tray in block 360. In one embodiment, the dust cover clamp can be manually loaded into the workspace, and in other embodiments, the dust cover can be automatically loaded. In block 365, the dust cover can be placed on the clamp, which may include centering, for example by a centering mechanism discussed herein, and glue can be dispensed (e.g., by a dispensing needle) onto the dust cover in block 363. In block 364, the dust cover can be picked up, flipped, and placed (e.g., manually and / or by a vacuum pen) onto the voice coil, and an activator can be applied in block 365, at which point the illustrative process ends.

[0080] By centering the components of a loudspeaker assembly according to common characteristics such as inner and / or outer diameters, and thereby aligning / centering the components with a common reference point (e.g., a common centering point or axis), the structure, consistency, orthogonality, and concentricity of the loudspeaker assembly can be improved. In an illustrative embodiment, the assembly system / mechanism may include a mechanical gripper with a centering mechanism. Certain components can be mechanically gripped and centered regardless of their characteristic dimensions and automatically placed on a common reference shared by all components. Such a configuration can advantageously reduce concentricity problems, reduce process variability, improve the acoustic performance of the loudspeaker, provide lower manufacturing costs, and reduce process defects.

[0081] Figure 3D-3H The illustration shows different stages of the assembly process for the motor assembly and other components in an illustrative embodiment. Figure 3-3C The process flow of one or more manufacturing units is shown. It should be understood that the term "unit" as used herein refers to one or more manufacturing units, which may include a set of resources required to manufacture a product such as a loudspeaker. These resources may include materials, machines, tools, and other production equipment, and may be arranged in very close proximity to enhance communication. Each unit referred to herein may be a separate unit or part of a group of units. Go to Figure 3D An example is provided for coupling a shortening ring to an upper washer in unit 362. Unit 362 can be configured to pick up the gap shortening ring using a dual gripper, such as a multi-finger clamp, in block 363. In block 364, adhesive can be applied to the upper washer (e.g., in a recessed holder) to couple with the shortening ring, wherein in block 365, the gap shortening ring can be placed (e.g., using a dual multi-finger clamp) and pressed (e.g., with a 4 kg downward force for 60 seconds, but other forces and pressing durations may be used without departing from the spirit and scope of the disclosed embodiments) onto the upper washer.

[0082] exist Figure 3E The document provides an example for coupling an upper washer to a lower washer in unit 366. Unit 366 may be a single unit or part of a combination of units in any of the embodiments disclosed herein. In block 376, the lower washer may be centered and picked up in block 367 (e.g., using a dual multi-finger gripper), and in block 368, adhesive may be dispensed onto the upper washer for coupling with the lower washer. The lower washer may then be placed (e.g., using a dual multi-finger gripper) on the upper washer and pressed down to couple the upper washer to the lower washer.

[0083] exist Figure 3FThe document provides an example for connecting a magnet to a lower washer in unit 370. Unit 370 may be a single unit or part of a combination of units in any of the embodiments disclosed herein. In block 371, the magnet is centered and picked up (e.g., using a dual multi-finger gripper), and in block 372, adhesive is applied to the lower washer to couple the magnet. In block 373, the magnet may be placed (e.g., using a dual multi-finger gripper) and pressed into the lower washer to couple the magnet to the lower washer. In one illustrative embodiment, a centering cone (or “centering clamp”) may be used to hold and center the components before and during connection. Further details regarding the centering clamp are provided below. Figures 7A-7E turn up.

[0084] exist Figure 3G The document provides an example for coupling a large shortening ring to a lower washer in unit 374. Unit 374 may be a single unit or part of a combination of units in any embodiment disclosed herein. In block 375, the large shortening ring may be picked up (e.g., using a dual multi-finger gripper), and in block 376, adhesive may be applied to the lower washer to couple the large shortening ring. In block 377, the large shortening ring may be placed (e.g., using a dual multi-finger gripper) and pressed into the lower washer to couple the large shortening ring to the lower washer.

[0085] exist Figure 3H The document provides an example for coupling the yoke to a magnet in unit 378. Unit 378 may be a single unit or part of a combination of units in any of the embodiments disclosed herein. The yoke may be picked up from a feeder in block 379 (e.g., using a dual multi-finger gripper), and a centering fixture is used in block 380 (see [link to documentation]). Figures 7A-7E Center it. In box 381, glue can be applied to the magnet to couple with the yoke, wherein the yoke is then picked up from a centering fixture (e.g., using a dual multi-finger gripper) and placed (e.g., using a dual multi-finger gripper) on the magnet and pressed down to secure the coupling in box 382. In some illustrative embodiments, the magnet may include pole pieces coupled to the yoke.

[0086] Those skilled in the art should understand that, Figure 3-3H The processes disclosed herein are illustrative only and are not intended to be limiting in any way. It should be understood that some processes may be performed in different orders (i.e., some parts may be placed before others and vice versa), and may include different unit configurations, as well as different manufacturing processes (e.g., manual, automatic) and different process steps. References to specific manufacturing equipment used (e.g., multi-finger grippers, vacuum grippers, dispensing pins, etc.) are provided for illustrative purposes only and should not be construed as limiting.

[0087] Figures 4A-4F The speaker assembly is shown at various stages of the assembly process, and one or more of the techniques described herein may be employed in various illustrative embodiments. Figure 4A A speaker assembly 400 configuration for placing and aligning an upper washer 304 onto a speaker basket 302 positioned on a tray 404, as shown in an illustrative embodiment, is illustrated. As shown, the speaker basket 302 may include terminals 316 for connecting the speaker assembly 400 to external circuitry. After adhesive is applied, the first (upper) washer 304 is coupled to the basket 302. In an illustrative embodiment, the speaker basket 302 may be coupled to the tray 404 via a centering clamp 708, as described below. Figure 7A - 7E discusses this in more detail. Tray 404 can be configured on the unit working surface 402.

[0088] Figure 4B This shows the shortening ring 306 being inserted into the upper washer 304. Figure 4A Examples of implementations. Figure 4C A speaker assembly 400 is shown having a second (lower) washer that is picked up and placed on a shortening ring and an upper washer. Figure 4D The speaker assembly 400 is shown after the lower shortening ring 310 is inserted. Figure 4E A magnet 312 coupled to a lower washer 308 via a lower shortening ring 310 (not visible in the figure) is shown. Next, Figure 4F The yoke 312 coupled to the magnet 312 is shown.

[0089] As discussed herein, certain components of a speaker assembly can be picked up, placed, and / or otherwise manipulated using a multi-finger gripper. In such exemplary embodiments, the fingers of a tapered circumferential gripper may apply outward and along the tapered shape to provide an outward alignment force on an open inner circumferential surface of a component or on multiple components having variable open inner circumferential surfaces; or an outer gripper may grasp one or more components surrounding an outer circumferential surface. While some embodiments may use a three-finger gripper, those skilled in the art will understand that other configurations (e.g., four-finger grippers) may also be used. Go to Figure 5 An illustrative embodiment of a 3- or 4-finger gripper 500 is shown, wherein the gripper can pick up, align, and / or place components on the speaker assembly 400 area as shown. Figures 6A-6C Various perspective views of the clamp 500 are shown.

[0090] Go to Figure 7A A perspective view of a centering clamp 702 coupled to a tray 404 in an illustrative embodiment is shown. Referring now to... Figure 7BAs can be seen, the centering clamp 702 is coupled to the tray 404 via a centering mechanism 704, which passes through the front or top surface of the tray 404 and is coupled to the centering pin 708. As shown, the tray 404 can be hollowed out to receive the centering mechanism 702. The connected centering mechanism 704 and pin 708 may also include an elastic member 706, such as a spring, for secure coupling. The spring can be made of spring steel or other suitable material.

[0091] In use, the centering clamp 702 can operate as a chuck, such as... Figure 7B As shown in the simplified side view, the centering clamp 702 has a generally cylindrical bottom portion extending into the tray and a generally conical top portion. Similar to a chuck, the centering clamp can be used with a centering mechanism 704 to press against the cone 712, reducing its inner surface to a slightly smaller diameter, pressing against components that need to be firmly held, such as speaker components (e.g., upper gaskets). Figure 7C As shown in the cross-sectional view, when the centering clamp is tightened, the jaws 710 can expand to press the centering clamp against the part, resulting in high static friction.

[0092] When the basin holder 302 is effectively secured to the tray 404 via the centering clamp 702, this provides for centering and coupling additional components (e.g. Figure 7D The advantageous configuration of the upper washer shown, followed by Figure 7E The remaining components shown in the example, Figure 7E A cross-sectional view of the speaker assembly is shown. Because these components are aligned more precisely in this way at multiple stages of the assembly process, misalignment and concentricity issues can be minimized. Furthermore, with the centering clamp 702 connected to tray 404 providing a more stable and consistent configuration for centering the speaker assembly components, speaker manufacturing can achieve more consistent concentricity from one assembly to the next (see below). Figure 10A-15B (and 16A-16B).

[0093] Figure 8A configuration for aligning and placing a component onto a portion of a speaker assembly using a multi-finger gripper is illustrated in an illustrative embodiment. Here, in this example, the gripper 802 comprises a three-finger gripper with a specially constructed gripper arm geometry, wherein each gripper arm 804 includes a lateral extension 804A and a lower protrusion 804B. The lateral extension 804 can typically be configured as an arcuate shape with square and / or rounded edges, wherein the arcuate shape defines a cavity for receiving at least a portion of the component (shown as dashed lines in the figure). This configuration can be advantageous for gripping components with a three-dimensional planar shape, such as washers or magnets. As shown, the lower protrusion portion 804B may include a protrusion extending laterally from the gripper or at an angle (e.g., 60-90°) relative to the lateral portion of the gripper arm. The lower protrusion portion 804B is advantageously configured to grip components that may require insertion, such as shortening rings. Each gripper arm can be made of steel, plastic, or any other suitable material and can be etched or patterned to provide additional gripping capabilities. In some illustrative embodiments, the gripper arm or finger, mentioned throughout, may include a pad or coating of rubber, plastic or other suitable material to increase or decrease friction and / or surface tension and gripping capacity.

[0094] Figures 9A-9B A dispensing device structure for dispensing washers and / or magnets is illustrated in illustrative embodiments. In these examples, the dispensing device 900 can be configured as a feed tray, wherein components such as washers 304, 308 and / or magnets 312 can be stacked on the tray 901 and secured by retaining posts 902 for gripping and placement by a multi-finger gripper or vacuum gripper. Although other feeding mechanisms (e.g., belts, gears, etc.) are contemplated in this disclosure, components on the tray 901 of the dispensing device 900 can be fed along a track 904 via a chain device 903. One or more dispensing devices 900 can be configured with units during the manufacturing process to provide a steady flow of components.

[0095] Using the techniques described herein, arranged components can be aligned and centered to increase concentricity at least partially throughout the assembly process. The component area (i.e., the area where the components are to be placed) has a measurement center. Components placed in the area have a centering reference, which is considered to have an eccentricity of 1 / 2 eccentricity relative to the measurement center. By increasing concentricity within and between assembly steps, the speaker assembly can be more robust and consistent from one component to the next.

[0096] Figure 10A-15BVarious data indicating concentricity measurements for different speaker assembly components are shown under various illustrative embodiments. Each figure shows the relative concentricity between multiple repeated placements of the various components, where each placement is represented by a point on the graph, and where placements of 0.000, 0.000 μm are considered absolutely concentric. A placement for a placement region 1102 (e.g., a 0.125 μm region) with a predetermined concentricity tolerance 1104 (e.g., a 0.075 μm region) is shown. Of course, for example, the tolerance can be reduced to obtain optimal performance due to improved concentricity, and the tolerance values ​​provided herein are merely exemplary. Figure 11A Similar placement areas and concentricity tolerances are shown (1202-04, 1304-04, 1402-04, 1502-04).

[0097] Figure 10A This shows the placement of the gap shortening ring relative to the upper washer in 10 positions ( Figure 10B Also combined above Figure 4B (For reference) an example where it can be seen that the placement (each represented by a point) is within the concentricity tolerance of 1104. Figure 11A The diagram shows the lower washer ring to the gap shortening ring / upper washer ( Figure 11B Also combined above Figure 4C The reference shows 10 examples of placements, where it can be seen that the placements (each represented by a point) are within a concentricity tolerance of 1104.

[0098] Similarly, Figure 12A Examples of 10 placements from the lower shortening ring to the lower washer are shown. Figure 12B Also combined above Figure 4D refer to), Figure 13A Examples of 10 placements of the magnet to the lower shortening ring are shown. Figure 13B Also combined above Figure 4E (Reference), and Figure 14A The diagram shows 10 placements of the yoke to the magnet. Figure 14B Also combined above Figure 4F (See the simulation example for reference). As can be seen from the figure, the corresponding placements (each represented by a point) are basically within the expected concentricity tolerance (1202-04, 1304-04, 1402-04, 1502-04). Figure 15A The relative motor assembly is shown between various components assembled using any of the techniques disclosed herein. Figure 15B A simulation example of the concentricity of the components, where the components are substantially within the concentricity tolerance (1604) of the placement area 1602.

[0099] Figure 16AData indicating the concentricity measurement results of the yoke to the upper washer under an illustrative embodiment are shown. The figure shows the concentricity measurements of the yoke placement on the upper washer, N=10 (using an average value of 0.0686063), where each bar represents one placement. Using a lower limit (LB) of 0 and an upper limit (UP) of 0.25, it can be seen that the concentricity of the yoke on the upper washer is perfectly within the acceptable range, with an overall standard deviation (StDev) of 0.0386898 and an intra-part standard deviation of 0.0397773. Of course, those skilled in the art should understand that… Figure 16A The diagram shown is merely an example, and this disclosure may involve a variety of other measurements for different configurations.

[0100] Figure 16B Data indicating overall concentricity measurements are shown in an illustrative embodiment. The figure shows the overall concentricity measurements for the assembly, N=10 (using an average of 0.119944), where each bar represents a placement. Using a lower specification limit (LSL) of 0 and a higher specification limit (USL) of 0.25, it can be seen that the overall concentricity is within acceptable limits, with an overall standard deviation (StDev) of 0.0138627 and an intra-part standard deviation of 0.0142523. Of course, those skilled in the art should understand that... Figure 16B The diagram shown is merely an example, and this disclosure may involve a variety of other measurements for different configurations.

[0101] Figure 17 Data on the centering repeatability of a pallet seat indicated by a three-jaw and four-jaw centering clamp chuck (e.g., 702) under an illustrative embodiment are shown. Since the number of jaws used on the centering clamp chuck affects clamping and centering on the component, it needs to be tested to determine the impact of using three-jaw and four-jaw centering clamp chucks on the repeated mounting of the component, thereby determining the consistency of concentricity. As can be seen from the figure, for mounting area 1802 with a concentricity tolerance of 1804, the three-jaw centering clamp chuck (shown as a rhombus in the figure) provides a tighter concentricity (shown as a square in the figure) compared to the four-jaw centering clamp chuck.

[0102] Figures 18A-18E Additional and alternative illustrative embodiments of the loudspeaker assembly process utilizing a five-unit manufacturing configuration are shown. Again, those skilled in the art should understand that... Figures 18A-18E The process described is for illustrative purposes only and is not intended to limit in any way, including but not limited to the specific order of steps, unit configuration / number of units, and specified devices used.

[0103] Figure 18AThe process for aligning and placing a lower shortening ring onto the yoke of a speaker assembly is illustrated in an illustrative embodiment. In this example, the yoke is provided as input 1902 to a first unit 1904, which may be configured to include a selectively compliant assembly robotic arm or a selectively compliant articulated robotic arm (SCARA), and may also include equipment including, but not limited to, a conveyor belt, a tray, a self-centering outer diameter (OD) gripper, a fixed dispensing station (deck tool), a ring feeder, and a programmable logic controller (PLC), as shown in 1908.

[0104] The illustrative process flow shown in 1906 may include exemplary steps such as: transferring a tray in; picking up a yoke from the tray; moving to a stationary dispensing station; dispensing glue to the lower shortening ring; dispensing glue to the magnet; placing the yoke on the tray; picking up the lower shortening ring from the feeder; placing the lower shortening ring on the yoke; applying a downward force (e.g., 2 kg for 10 seconds); and transferring the tray out. Once process 1906 is complete, unit output 1910 may include a yoke with the lower shortening ring attached and a magnet with glue dispensed thereon.

[0105] Turning Figure 18B , Figure 18A The unit output 1910 is provided as input 1912 to the second unit 1914, which can also be configured as a SCARA unit and may further include the conveyor belt, tray, self-centering mechanism, self-centering outer diameter (OD) gripper, magnet feeder, and programmable logic controller (PLC) shown in 1918. The illustrative process flow shown in 1916 may include the following steps: turning the tray in; centering; picking up the magnet; placing the magnet; applying a downward force (e.g., 2 kg for 10 seconds); and turning the tray out. Once process 1916 is complete, the unit output 1920 may include a yoke with a lower shortening ring connected to it and with the magnet attached.

[0106] Go to Figure 18C , Figure 18B The unit output 1920 shown is provided as input 1922 to the third unit 1914. The third unit 1924 can also be configured as a six-axis unit and may also include a conveyor belt, a tray, a self-centering mechanism, a self-centering inner diameter (ID) gripper, a fixed dispensing station (which may include deck tools), a washer feeder, and a PLC controller, as shown in 1928. The illustrative process flow shown in 1926 may include the following steps: turning the tray in; centering; picking up the lower washer; moving to the fixed dispensing station and flipping it; dispensing the glue pattern; flipping and placing the lower washer; applying a downward force (e.g., 2 kg for 10 seconds); and turning the tray out. Once process 1926 is complete, unit output 1930 may include a yoke connected to a lower shortening ring, a magnet, and a lower washer.

[0107] Go to Figure 18D , Figure 18C The unit output 1930 shown is provided as input 1932 to the fourth unit 1934. The fourth unit 1934 can also be configured as a six-axis unit and may also include a conveyor belt, a tray, a self-centering mechanism, a self-centering ID holder, a double-ended actuator with a self-centering ID holder and a dispensing pin, a ring feeder, and a PLC controller, as shown in 1938. The illustrative process flow shown in 1936 may include the following steps: turning the tray in; centering; dispensing glue to the gap shortening ring; dispensing glue to the upper washer; picking up the gap shortening ring; placing the gap shortening ring; applying a downward force (e.g., 2 kg for 10 seconds); and turning the tray out. Once process 1936 is complete, unit output 1940 may include a yoke connected to the lower shortening ring, magnet, lower washer, gap shortening ring, and glue for the upper washer.

[0108] Go to Figure 18E , Figure 18D The unit output 1940 shown is provided as input 1942 to the fifth unit 1944. The fifth unit 1944 can also be configured as a six-axis unit and may also include a conveyor belt, tray, centering mechanism, self-centering ID gripper, basket / upper washer (B / UW) feeder, and PLC controller as shown in 1948. The illustrative process flow shown in 1946 may include the following steps: turning the tray in; centering; picking up the B / UW sub-assembly; placing the B / UW sub-assembly; applying a downward force (e.g., 2 kg for 10 seconds); and turning the tray out. Once process 1946 is complete, unit output 1950 may include a speaker assembly including a yoke connected to a lower shortening ring, a magnet, a lower washer, a gap shortening ring, and the B / UW assembly.

[0109] Figures 19A-19E Another illustrative embodiment of the loudspeaker assembly process utilizing a four-unit manufacturing configuration is shown. Again, those skilled in the art should understand that... Figures 19A-19E The process described is for illustrative purposes only and is not intended to limit in any way, including but not limited to the specific order of steps, unit configuration / number of units, and specified devices used.

[0110] Figure 19A The illustration shows a process for aligning and connecting a B / UW sub-assembly to a shortening ring under a value, in an illustrative embodiment. In this example, the B / UW sub-assembly is provided as an input 2002 for a first unit 2004, which may be configured as a six-axis unit and may also include devices including, but not limited to, a conveyor belt as shown in 2008, a tray with a centering clamp, a double-ended actuator with a self-centering gripper and a dispensing pin, a ring feeder, and a PLC controller.

[0111] An illustrative process flow as shown in 2006 may include the following steps:

[0112] - Transfer the tray in;

[0113] - Center & Pickup gap shortening loop;

[0114] - Dispense adhesive into the gap shortening ring;

[0115] - While placing the gap shortening ring, apply an outward force to the ID, for example, using a three-finger gripper, to set the center position;

[0116] - Apply a downward force (e.g., 4 kg, for 60 seconds); and

[0117] - Release and rotate the tray out.

[0118] Once process 2006 is complete, unit output 2010 may include a B / UW sub-component with a coupled gap shortening ring.

[0119] Go to Figure 19B ,Will Figure 19A The unit output 2010 is provided as input 2012 to the second unit 2014, which can be configured as a SCARA unit and may also include a conveyor belt, a tray with a centering clamp, a self-centering vacuum gripper, a washer feeder, and a PLC controller, as shown in 2018. Based on the discussion herein, those skilled in the art will recognize that although the process automation discussed herein may be referenced with respect to specific exemplary embodiments, such as a 6-axis or SCARA robot or a PLC motion controller, the process is not so limited and any high-precision manipulators and controllers (i.e., PCs or PLCs) can be deployed. The system can also employ hard automation or flexible automation. Furthermore, other aspects illustratively discussed herein, such as the use of vacuum and / or mechanical grippers, are merely exemplary in nature, and other aspects, such as other gripping techniques, may be utilized. Now, specifically returning to the exemplary embodiment shown in Figure 19, the illustrative process flow shown in 2016 may include the following steps:

[0120] - Transfer the tray in;

[0121] - Apply adhesive to the lower washer;

[0122] - Center and pick up the lower washer;

[0123] - While placing the lower washer, apply an outward force to ID, for example, using a centering cone, to set the center position;

[0124] - Apply a downward force (e.g., 4 kg, for 60 seconds); and

[0125] - Release the clamp and rotate the tray out.

[0126] Once process 2016 is complete, unit output 2020 may include a B / UW sub-assembly with a coupled gap shortening ring and a lower washer.

[0127] Go to Figure 19C , Figure 19B The unit output 2020 is provided as input 2022 to the second unit 2024, which can be configured as a SCARA unit and may also include a conveyor belt, a tray with a centering fixture, a self-centering vacuum gripper, a magnetic feeder, and a PLC controller, as shown in 2028. The illustrative process flow shown in 2026 may include the following steps:

[0128] - Apply glue to the magnet;

[0129] - Center & Pick up the magnet;

[0130] - While placing the magnet, for example, use a centering cone to apply an outward force to the ID to set the center position;

[0131] - Apply a downward force (e.g., 4 kg, for 60 seconds); and

[0132] - Release the clamp and then rotate the tray out.

[0133] - Turn the tray out

[0134] Once process 2026 is complete, unit output 2030 may include a B / UW subassembly with a coupled gap shortening ring, lower washer, and magnet.

[0135] Go to Figure 19D , Figure 19C The unit output 2030 is provided as input 2032 to the third unit 2034, which can be configured as a six-axis unit and may also include a conveyor belt as shown in 2038, a tray with a centering fixture, a double-ended actuator with a self-centering gripper and a dispensing pin, a ring feeder, and a PLC controller. The illustrative process flow shown in 2036 may include the following steps:

[0136] - Transfer the tray in;

[0137] - Dispense adhesive for the lower shortening ring;

[0138] - Center and pick up the shortened ring from the feeder;

[0139] - While placing the shortening ring, apply an outward force to the ID, for example, using a three-finger gripper, to set the center position;

[0140] - Apply a downward force (e.g., 4 kg, for 60 seconds); and

[0141] - Release the clamp and then rotate the tray out.

[0142] - Turn the tray out.

[0143] Once process 2036 is complete, unit output 2040 may include a B / UW sub-assembly with coupled gap shortening ring, lower washer, magnet, and lower shortening ring.

[0144] Go to Figure 19E , Figure 19D The unit output 2040 is provided as input 2042 to the fourth unit 2044, which can be configured as a SCARA unit and may also include a conveyor belt, a tray with a centering fixture, a deck tool centering fixture, a distribution station (deck tool), a vacuum gripper, a yoke feeder, and a PLC controller, as shown in 2048. The illustrative process flow shown in 2046 may include the following steps:

[0145] - Transfer the tray in;

[0146] - Pick up the yoke;

[0147] - Place the yoke on the centering clamp mounted on the deck;

[0148] - Distribute glue to the yoke;

[0149] - Pick up the yoke from the centering clamp mounted on the deck (centered on the clamp);

[0150] - Place the yoke; and

[0151] - Apply a downward force (e.g., 2 kg, for 60 seconds); and

[0152] - Release the clamp and rotate the tray out.

[0153] - Turn the tray out.

[0154] Once process 2046 is complete, unit output 2048 may include a B / UW sub-assembly with a coupled gap shortening ring, lower washer, magnet, lower shortening ring and yoke.

[0155] Figures 20A-20C Another illustrative embodiment of a speaker assembly process utilizing a speaker motor assembly with a multi-unit manufacturing configuration is shown. Figures 20A-20C In the example, the unit can be a combination of the above. Figures 19A-19EThis is part of the unit configuration discussed. Again, those skilled in the art should understand that... Figures 20A-20C The process described is for illustrative purposes only and is not intended to limit in any way, including but not limited to the specific order of steps, unit configuration / number of units, and specified equipment used.

[0156] Figure 20A The illustration depicts the process for aligning and coupling a loudspeaker motor assembly with a voice coil, voice coil gauge, and spider, according to an illustrative embodiment. In this example, the motor assembly and voice coil gauge are provided as a first unit 2102 to a fifth input unit 2104 (from...). Figures 19A-19E (Continuing with the example of the four-unit combination), the fifth unit 2104 can be configured as a six-axis unit and may also include equipment, including but not limited to a conveyor belt as shown in 2008, a tray with a centering clamp, a double-ended actuator with a self-centering gripper and a dispensing pin, a ring feeder and a PLC controller.

[0157] The illustrative process flow shown in 2106 may include the following steps:

[0158] - Transfer the tray in;

[0159] - Disengage the motor clamp;

[0160] - The motor is clamped by the yoke;

[0161] - Engage the motor clamp;

[0162] - Center and pick up the voice coil using the voice coil gauge;

[0163] - Insert the voice coil into the spider (pick up the spider);

[0164] - Apply adhesive to the spinneret for placement;

[0165] - Place the voice coil gauge on the yoke;

[0166] - Place the sponge on the basin stand (apply 1kg of force for 2 seconds).

[0167] -Release the clamp;

[0168] - Apply adhesive to the voice coil / spangle joint; and

[0169] - Turn the tray out.

[0170] Once process 2106 is complete, unit output 2110 may include a central motor assembly coupled to the voice coil, voice coil gauge, and spider.

[0171] Go to Figure 20B , Figure 20AThe unit output 2110 is provided as input 2112 to the sixth unit 2114, which can be configured as a six-axis unit and may also include a conveyor belt as shown in 2118, a tray with a centering fixture, a self-centering vacuum gripper, a washer feeder, and a PLC controller. The illustrative process flow shown in 2116 may include the following steps:

[0172] - Transfer the tray in;

[0173] - Pick up the cone / suspension edge;

[0174] - Apply adhesive to the overhang edge;

[0175] - Apply a downward force (e.g., 5 kg, for 0.1 seconds).

[0176] - Release the clamp;

[0177] - Apply adhesive to the voice coil / cone joint; and

[0178] - Turn the tray out.

[0179] Once process 2116 is complete, unit output 2120 may include a centering motor assembly coupled to the voice coil, voice coil gauge, spider, and diaphragm / sidewall.

[0180] Go to Figure 20C , Figure 20B The unit output 2120 is provided as input 2122 to the sixth unit 2114, which can be configured as a six-axis unit and may also include a conveyor belt, a tray with a centering fixture, a self-centering vacuum gripper, a washer feeder, and a PLC controller, as shown in 2128. The illustrative process flow shown in 2126 may include the following steps:

[0181] - Load tray; and

[0182] - Apply adhesive to the dust cover;

[0183] - Pick up and place the dust cover.

[0184] Once process 2126 is complete, unit output 2120 may include a centering motor assembly coupled to the voice coil, voice coil gauge, spider, cone / suspension, and dust cover.

[0185] Figures 21A-21D Another illustrative embodiment is provided, wherein illustrative process steps performed at the respective units (1-6) configured with the disclosed equipment / tools are shown in tabular form. Figure 21A -B provides an illustrative unit-by-unit process for motor assemblies, while Figure 21B-C provides an illustrative unit-by-unit process for suspension components. Again, those skilled in the art should understand that... Figures 21A-21D The process described is for illustrative purposes only and is not intended to limit in any way, including but not limited to the specific order of steps, unit configuration / number of units, and specified devices used.

[0186] As can be seen from the foregoing detailed description, for the purpose of brevity in this disclosure, various features have been combined together in individual embodiments. This approach to disclosure should not be construed as reflecting an intention that subsequent claimed embodiments require more features than expressly recited in each claim.

[0187] Furthermore, this disclosure is provided so that any person skilled in the art can implement or use the disclosed embodiments. Various modifications to this disclosure will be apparent to those skilled in the art, and other variations can be applied to the general principles defined herein without departing from the spirit or scope of this disclosure. Therefore, this disclosure is not limited to the examples and designs described herein, but is given the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method of forming a speaker assembly comprising: first placing at least one upper gasket on a centering fixture, the centering fixture configured to secure and center the upper gasket, the centering fixture comprising a tray mounted collet, the collet comprising a plurality of jaws configured to secure the upper gasket; the collet being secured to the tray prior to placing the upper gasket on the centering fixture, and the plurality of jaws being mechanically extended after the upper gasket is placed; actively and mechanically determining a base plane based on a center of the upper gasket, wherein the base plane comprises a reference for orthogonality and alignment; and after the determining, automatically placing and physically engaging one or more components comprising at least one magnet and a speaker yoke on the upper gasket, wherein each of the one or more components is aligned with the base plane; wherein the speaker yoke is operatively coupled to the magnet.

2. The method of claim 1, wherein the one or more components comprise a lower gasket.

3. The method of claim 2, wherein the one or more components further comprise a lower shorting ring and a gap shorting ring.

4. The method of claim 3, wherein the placing and engaging of the one or more components comprises: placing and engaging the upper gasket to a speaker basket; placing and engaging the gap shorting ring to the upper gasket; placing and engaging a lower gasket to the gap shorting ring; and placing and engaging the lower shorting ring to the lower gasket.

5. The method of claim 4, wherein placing and engaging the magnet comprises placing and engaging the magnet on the lower gasket via the lower shorting ring.

6. The method of claim 1, wherein placing and engaging the one or more components comprises mechanically picking up each of the one or more components with a mechanical gripper comprising a centering mechanism.

7. The method of claim 6, wherein the centering mechanism comprises a plurality of fingers, and further comprising using the plurality of fingers to grip each of the one or more components using one of an inner diameter and an outer diameter of each of the one or more components.

8. The method of claim 1, wherein placing the magnet comprises picking up the magnet with a mechanical gripper comprising a centering mechanism.

9. The method of claim 8, wherein the centering mechanism comprises a plurality of fingers, and further comprising using the plurality of fingers to grip the magnet using one of an inner diameter and an outer diameter of the magnet.

10. The method of claim 1, wherein placing the speaker yoke comprises picking up the speaker yoke via a vacuum gripper.

11. A speaker assembly comprising: a speaker basket and an associated gasket, the gasket connected to the speaker basket and having a common concentricity; one or more components, the one or more components sequentially associated with the connection and having a substantially common concentricity; a magnet, the magnet sequentially associated with the one or more components and having a substantially common concentricity; a speaker yoke coupled to and sequentially associated with the magnet; and a speaker basket and an associated gasket, the gasket connected to the speaker basket and having a common concentricity; A centering clamp physically associated with the connection, the centering clamp including a collet having a plurality of jaws configured to secure the connection, wherein the centering clamp includes a tray, and wherein the collet is secured to the tray.

12. The speaker assembly of claim 11, wherein the one or more components include a lower gasket.

13. The speaker assembly of claim 12, wherein the one or more components include a lower shorting ring and a gap shorting ring.

14. The speaker assembly of claim 13, wherein an upper gasket is first associated with the speaker basket on one side thereof, and the gap shorting ring is associated with the other side of the upper gasket.

15. The speaker assembly of claim 14, wherein the lower gasket is associated with the upper gasket on one side by the gap shorting ring, and is associated with the lower shorting ring on the other side of the lower gasket.

16. The speaker assembly of claim 15, wherein the magnet is associated with the lower gasket by the lower shorting ring.

Images