Adaptive Damper Support for Pin Insertion in Stacked Planar Parts
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Solution Overview
Problem
Existing systems for assembling thin electronic components, such as smartphone and laptop parts, face challenges in joining fragile materials like thin plastic or metal sheets with irregular thickness or flatness, as they tend to deform under punching forces during pin insertion, and lack effective mechanisms to monitor and adjust for wear in support structures.
Innovation Solution
A system comprising a damping module with a resilient component and a compensatory mechanism that adjusts the position of a damper head to absorb compression forces and adapt to wear, using a microcontroller to monitor pressing cycles and adjust the distance between the damper head and the pressing ram, ensuring consistent support and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If point support is provided right underneath the pin holes to cushion punching force, then the mechanical resistance of the pieces against punching force is reinforced, but the point support becomes worn or torn after repetitive compression force
Solution Approach 1:
The support module is made movable along the vertical axis through a compensatory mechanism, allowing it to dynamically adjust its position and absorb wear through movement rather than remaining fixed. This transforms the static support structure into a dynamic one that can self-compensate for wear accumulation.
Solution Approach 2:
A sensor detects the position of the support module and provides feedback to a controller, which then actuates the compensatory mechanism to maintain the correct support position. This closed-loop feedback system ensures the support module automatically compensates for wear without manual intervention.
2Adaptability or versatility
If the planar objects have irregular thickness or flatness for functional and aesthetic reasons, then the design flexibility is improved, but the objects deform under punching force during pin insertion
Solution Approach 1:
The support module provides localized point support directly at the pin hole position rather than requiring uniform support across the entire planar object. This concentrated local support counteracts the punching force exactly where needed, preventing deformation of irregularly shaped objects while maintaining their overall geometric flexibility.
3Device complexity
If a fixed support position is used for pin insertion, then the system structure is simple, but it cannot adapt to wear of the support module after prolonged operation
Solution Approach 1:
The support module automatically compensates for its own wear through the compensatory mechanism without requiring external intervention or system shutdown. The sensor continuously monitors the support position, and the controller automatically actuates the adjustment mechanism, enabling the system to self-correct for wear accumulation during continuous operation.
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
The system effectively prevents deformation of planar objects during pin insertion by dynamically adjusting the support mechanism to account for wear, maintaining mechanical integrity and accuracy in assembly processes.
Implementation Method 1
a resilient component interposing in between the damper and the support
Data Source
AI summary
The disclosed system generally comprises a damping module, a pressing module, a placement platform for placement of the multiple stacked planar objects and a compensatory mechanism engaging to the damping module. Particularly, the damping module includes a damper, a resilient component and an elongate support which are all arranged within a holder. Each of the stacked planar objects has a top planar surface and an underside planar surface as well as carries a plurality of corresponding holes, which become aligned accordingly to form a plurality of longitudinal grooves upon placement onto the platform. The head portion of the damper is substantially aligning with the positioned groove and abutting onto the underside surface of the bottommost stacked object. The compensatory mechanism is capable of adaptively adjusting position of the head portion of the damper in relation to the pressing ram at the vertical and/or horizontal plane.