Assembly Jig Light Array for Hose Component Placement
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Solution Overview
Problem
The existing methods for assembling multiple components are labor-intensive and costly, requiring extensive measurement and the use of numerous custom-designed wooden jigs, which consume time and resources, especially when producing various types of hose assemblies.
Innovation Solution
A system comprising an assembly jig with a light array controlled by a controller, which receives assembly identification parameters to generate visual indications for component placement, eliminating the need for precise measurements and reducing the necessity for multiple jig designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional measurement methods are used to locate component installation positions, then assembly precision can be achieved, but assembly time and labor intensity increase significantly
Solution Approach 1:
The patent pre-markes the assembly jig with multiple position indicators corresponding to different component types and installation locations. Before assembly begins, all possible component positions are predetermined and visually marked on the jig surface. During assembly, operators simply need to place components on the illuminated positions without measurement, as the correct positions are pre-established and visually guided.
Solution Approach 2:
The patent replaces the traditional mechanical measurement system (rulers, calipers, tape measures) with an optical illumination system. LED lights embedded in the jig surface provide visual guidance for component placement, eliminating the need for operators to physically measure and calculate positions. The optical system projects light patterns that directly indicate where components should be placed.
2Manufacturing precision
If multiple custom-designed wooden jigs are created for different hose assembly types, then assembly precision for various products is maintained, but manufacturing cost and storage requirements increase
Solution Approach 1:
The patent designs a universal assembly jig with programmable LED illumination that can accommodate multiple hose assembly types. The jig contains numerous position indicators that can be selectively illuminated based on the specific assembly type being produced. By programming the LED system with different illumination patterns, the same physical jig can guide assembly for various hose configurations, replacing the need for multiple dedicated jigs.
Solution Approach 2:
The patent changes the illumination parameters (which LEDs are activated, their brightness, and patterns) based on the specific hose assembly type being produced. The controller receives assembly type information and adjusts the LED illumination accordingly, allowing one jig structure to serve multiple functions by dynamically changing its visual guidance parameters rather than requiring physical reconfiguration.
3Reliability
If extensive measurement and inspection processes are implemented, then assembly quality is ensured, but production efficiency and cost increase
Solution Approach 1:
The assembly jig provides self-inspection capability through its illuminated position indicators. The LED system visually confirms correct component placement in real-time during assembly, eliminating the need for separate inspection steps. Operators can immediately verify whether components are positioned correctly by observing the illumination patterns, allowing the assembly process to self-verify accuracy without additional inspection equipment or time.
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
This approach significantly reduces assembly time and costs by providing clear visual cues for component placement, allowing for efficient assembly of various components without the need for extensive jig customization or measurement, thereby enhancing productivity and reducing storage and inspection requirements.
Implementation Method 1
a light array, disposed along the assembly jig
Data Source
AI summary
A method for forming an assembly of a plurality of components. The method includes receiving, by a controller, one or more assembly identification parameters and controlling, by the controller, a light array disposed along an assembly jig based on the one or more assembly identification parameters.