Automated Mandrel Bend Test for Flexible Electronics
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Solution Overview
Problem
Manual mandrel bend tests for flexible electronics are tedious, slow, and fail to achieve consistent bend radii, limiting the number of bends that can be performed within a short schedule, especially when requiring up to 840,000 bends.
Innovation Solution
An automated bend test device with a controlled motor, drive shaft, nose piece, and mounting structures, along with a control system that allows for programmable angular rotation, speed, and cycle control, ensuring consistent bending across defined radii edges, thereby increasing repeatability and reducing manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual bending process is used, then operator can perform the test, but the testing is tedious, slow, and requires significant time
Solution Approach 1:
The patent replaces the manual mechanical bending operation with an automated motor-driven system. The motor rotates the mandrel to bend the flexible circuit board, eliminating the need for manual operator intervention and significantly increasing testing speed and consistency.
Solution Approach 2:
The automated testing system performs the bending operation autonomously without requiring continuous human intervention. The motor-controlled mandrel rotation and automated positioning enable the system to conduct multiple bend cycles independently, improving productivity while maintaining ease of operation through initial setup.
2Ease of operation
If manual bending is performed, then testing can be conducted, but consistent bend radius of 1 millimeter cannot be achieved
Solution Approach 1:
The manual bending operation is replaced with a motor-driven automated system that rotates the mandrel with precise control. This mechanical substitution ensures consistent bend radius by eliminating human variability in applying bending force and maintaining uniform rotation speed throughout the testing process.
Solution Approach 2:
The system maintains precise control over critical parameters including rotation speed, bend radius, and cycling frequency. By automatically controlling these parameters, the system achieves consistent 1 millimeter bend radius across all test cycles, unlike manual operation where parameter variability is inherent.
3Quantity of substance
If more bends are performed to meet schedule requirements, then testing coverage increases, but the shortened schedule cannot accommodate manual bending speed
Solution Approach 1:
The automated motor-driven system performs bending operations continuously without the breaks and repositioning required in manual testing. This substitution enables the system to complete up to 840,000 bends within the shortened schedule, dramatically increasing the quantity of bends achievable within limited time.
Solution Approach 2:
The automated system maintains continuous bending action throughout the testing period without interruption. The motor-driven mandrel rotation operates continuously through programmed cycles, maximizing the number of bends performed within the available time frame and eliminating idle time associated with manual operation.
4Productivity
If automated system is implemented, then productivity and repeatability increase, but device complexity increases
Solution Approach 1:
While the patent introduces a motor-driven automated system that increases productivity and repeatability, the complexity is managed by using a straightforward mechanical rotation mechanism. The motor controls mandrel rotation to bend the flexible circuit board, providing automation benefits without overly complex mechanisms.
Solution Approach 2:
The automated mandrel bending system is designed to be adaptable to different flexible circuit board configurations and testing requirements. The motor-controlled rotation mechanism can accommodate various bend radii, cycling frequencies, and test durations, providing multi-functionality that justifies the increased device complexity through enhanced productivity and repeatability.
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 automated system significantly increases the efficiency and consistency of mandrel bend tests, enabling a higher number of bends to be performed within a shorter timeframe while maintaining precise control over the bend radius, thus addressing the limitations of manual testing.
Implementation Method 1
The motor is connected to the drive shaft and rotates the drive shaft in response to control signaling provided by the control system. The rotating drive shaft in turn rotates the nose piece. Rotation of the nose piece bends the mounted DUT.
Implementation Method 2
The weight maintains a downward tension of the hanging portion of the device under test to enable bending of the device under test to conform to the radius of the first radius edge and the second radius edge of the mandrel.
Data Source
AI summary
A bend test device and bend test method enable a mandrel bend test to be automatically performed. The bend test device includes a controlled motor, a drive shaft coupled to the motor, a nose piece coupled to the drive shaft, and a nose clamp for securing a device under test (DUT) to the nose piece. A control system connected to the bend test device uses a programmed control algorithm to control the bend test device. The motor is connected to the drive shaft and rotates the drive shaft in response to control signaling provided by the control system. The rotating drive shaft in turn rotates the nose piece. Rotation of the nose piece bends the mounted DUT. The motor rotates the drive shaft as defined by the software parameters and the DUT is bent back and forth across a defined radius edge.