Acoustic Levitation for Contactless Component Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing assembly methods for manufacturing components, such as plastic, glass, metal, and electronic components, require separate production and manual assembly, leading to increased production costs and complexity due to the limitations of contact assembly techniques, especially for small components with different physical characteristics.
Innovation Solution
A contactless acoustic manipulation system using acoustic levitation and transducer arrays controlled by a computing unit to suspend and transport materials and components in three-dimensional space, allowing for the assembly of products from various materials and components without direct contact, using acoustic fields to position and join materials through focused energy application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If contact assembly techniques are used for small components, then assembly can be performed with conventional equipment, but electric field forces prevent release of objects from grippers and manipulation of materials with different physical characteristics becomes complicated
Solution Approach 1:
The patent replaces mechanical contact-based assembly systems with an acoustic field-based manipulation system. Acoustic transducers generate standing waves that create acoustic radiation pressure to levitate and position components without physical contact, eliminating the problem of electric field forces preventing gripper release and simplifying manipulation of diverse materials.
Solution Approach 2:
The patent introduces an acoustic field as an intermediary between the manipulation system and the components. This acoustic medium serves as a non-contact interface that can manipulate various materials (plastic, glass, metal, electronic components) without direct mechanical contact, resolving the complexity of handling materials with different physical characteristics.
2Manufacturing precision
If separate production and assembly equipment are used, then each process can be optimized independently, but additional production time and higher production costs result
Solution Approach 1:
The patent merges separate production and assembly operations into a single integrated system. The acoustic manipulation system can both manufacture components (through acoustic levitation and positioning of material) and assemble them into final products without requiring transfer between separate equipment, thereby eliminating additional production time while maintaining manufacturing precision through continuous acoustic field control.
Solution Approach 2:
The acoustic manipulation system performs multiple functions: it can manufacture individual components, transport them through three-dimensional space, position them with high precision, and assemble them into final products. This multi-functional capability eliminates the need for separate production and assembly equipment while maintaining optimization of each process stage.
3Productivity
If acoustic levitation is used for positioning small objects, then operational speed and spatial resolution increase, but the system becomes more complex compared to contact assembly
Solution Approach 1:
The acoustic transducer array is segmented into multiple independently controllable elements arranged in specific geometric patterns. Each transducer can be individually addressed and controlled to generate specific acoustic radiation pressure patterns, enabling precise manipulation of multiple components simultaneously at high speed while managing system complexity through modular control architecture.
4Measurement precision
If acoustic transducers are controlled to create standing waves for particle suspension, then three-dimensional positioning is achieved, but energy consumption increases
Solution Approach 1:
The acoustic transducers operate in periodic cycles, generating standing waves only when and where components need to be manipulated or positioned. The system activates specific transducer groups temporarily to create acoustic radiation pressure patterns, then deactivates them when manipulation is complete, reducing overall energy consumption while maintaining high spatial positioning precision during active manipulation periods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and precise assembly of complex products with reduced production costs and increased operational speed, allowing for the use of multiple materials and joining methods, including melting and welding, while maintaining high spatial resolution and operational speed.
Implementation Method 1
One application of a three-dimensional acoustic manipulation technology is positioning small-scale objects in three-dimensional space using acoustic levitation
Implementation Method 2
acoustic transducer arrays... controlled by a computing unit to suspend and transport materials and components
Implementation Method 3
acoustic field with the maximum and minimum (nodes) points is created in the focus area due to interference of waves being emitted from the transducers
Implementation Method 4
at least one material and/or component joining (melting, solidifying or welding) device... focused energy application
Data Source
Figure 1
Figure 2
AI summary
Apparatus for contactless manipulation of material and components, such as electronic components, comprises of material and/or component feed devices (5); acoustic transducer arrays (1); at least one material and/or component joining (melting, solidifying, welding) device (6); base (8) on which object is formed; a computing unit with an executable program. The program is used to control acoustic transducers that generate an acoustic field required for particle manipulation. Said control program can receive and process a signal coming from a feedback device in order to estimate position of material particles or components and improve manipulation accuracy.