Orthodontic Archwire Bending With 6-DOF Jointed Manipulators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machines for bending orthodontic archwires are limited in precision and range of shapes they can produce, often requiring multiple steps and resulting in inaccuracies and increased manufacturing costs due to the need for iterative bending processes to achieve desired geometries.
Innovation Solution
A compact bending machine with a combination of revolute and prismatic joints arranged in orthogonal axes, allowing for precise control of orthodontic archwires to be bent in six degrees of freedom, enabling the creation of complex shapes with improved accuracy and reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single compact bending machine with multiple degrees of freedom is used, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The bending machine is divided into multiple independent bending units, each capable of performing a specific bending operation. This segmentation allows the system to achieve complex six-degree-of-freedom bending capabilities through coordinated operation of simpler modular components, resolving the contradiction between precision and complexity.
Solution Approach 2:
The bending machine is designed as a multi-functional device that can perform multiple bending operations (torque, rotation, angulation) and accommodate different archwire types and bracket configurations. This universality allows a single complex machine to replace multiple simpler machines, improving precision while the modular design manages the complexity.
2Adaptability or versatility
If multiple iterative bending steps are used, then adaptability to different archwire shapes is improved, but loss of time and productivity decrease
Solution Approach 1:
The bending machine is pre-configured with multiple bending units and control systems that can execute complex bending sequences in a single automated operation. This preliminary preparation of the machine architecture allows it to perform what would traditionally require multiple iterative steps, thereby maintaining adaptability while dramatically improving productivity.
Solution Approach 2:
The bending process is designed as a continuous automated operation where multiple bending units work in sequence without interruption. This eliminates the downtime and repositioning required in traditional iterative processes, maintaining full adaptability to different archwire shapes while ensuring continuous productive action throughout the manufacturing process.
3Adaptability or versatility
If multiple bending steps are required, then adaptability to complex geometries is improved, but loss of substance increases due to wire waste
Solution Approach 1:
The archwire is divided into multiple segments, each corresponding to a specific bending unit's operation. This segmentation allows precise control over each portion of the wire, enabling complex geometries to be achieved with minimal material waste since each bending unit works on a predetermined segment rather than requiring multiple attempts on the entire wire.
Solution Approach 2:
The bending sequence and parameters are pre-calculated and programmed based on the desired final geometry. This preliminary planning ensures that each bending unit applies the exact necessary deformation in a single pass, eliminating the need for iterative adjustments that would consume additional wire material and reduce overall substance efficiency.
Data Source
AI summary
An apparatus and method for bending or shaping orthodontic archwires or other medical devices into a complex, patient individual shape is described. The apparatus comprises of two moveable, compact, manipulators with, in total, at least three revolute joints defining three rotation axes and at least three prismatic joints defining at least three translation axes. Gripping tools are provided on the manipulators. The two manipulators are arranged to allow a relative movement in six degrees of freedom. A reduced complexity embodiment is also described having only one or two revolute joints.