Automated Washer Insertion for Faster Molded Part Assembly
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Solution Overview
Problem
Current assembly processes for molded products with mechanical fasteners, such as washers, are slow, labor-intensive, and pose safety risks due to manual insertion methods, increasing costs and time in manufacturing.
Innovation Solution
An automated insertion system with a frame, motors, and actuator assemblies that move along three axes to precisely align and insert fastener components into molded parts, reducing manual labor and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual labor and manually operated presses are used to insert washers into molded parts, then the process is simple to implement, but the assembly time and labor costs increase significantly
Solution Approach 1:
The patent replaces manually operated mechanical presses with an automated insertion system that uses a robotic arm, computer-controlled positioning, and automated press mechanism. This substitution eliminates manual labor while significantly increasing assembly speed and precision, directly resolving the contradiction between ease of implementation and productivity.
Solution Approach 2:
The system enables self-service automation where the insertion apparatus autonomously performs washer placement without human intervention. The computer-controlled system automatically positions, aligns, and inserts washers into molded parts, maintaining simplicity of operation while dramatically improving assembly throughput.
2Device complexity
If manual insertion methods are used, then the equipment complexity is low, but the labor costs and safety risks increase
Solution Approach 1:
The patent replaces manual insertion operations with an automated robotic system that eliminates human exposure to repetitive strain injuries and safety hazards. The computer-controlled apparatus performs all insertion tasks autonomously, reducing equipment complexity concerns while eliminating safety risks associated with manual labor.
Solution Approach 2:
The system introduces an automated insertion apparatus as an intermediary between the washer components and molded parts, eliminating direct human interaction with the insertion process. This intermediary mechanism handles all potentially harmful operations while maintaining operational simplicity through computer control.
3Adaptability or versatility
If multiple washers are inserted using manual methods, then the process is flexible to adapt, but the assembly time and realignment requirements increase
Solution Approach 1:
The patent replaces manual insertion methods with an automated system that uses computer-controlled positioning to rapidly and precisely insert multiple washers without realignment. The robotic arm and automated press mechanism maintain the flexibility to handle different washer configurations while eliminating time losses associated with manual repositioning and realignment.
Solution Approach 2:
The automated insertion system is designed with universal capabilities to handle multiple washer types, sizes, and configurations through programmable control. This multi-functional apparatus can adapt to different assembly requirements while maintaining high speed and precision, resolving the contradiction between flexibility and assembly time.
Data Source
AI summary
An automated insertion system for inserting or combining one or more fastener components with a molded part. The automated insertion system can handle multiple fastener components repeatedly, and do so faster and more safely than current processes.