Automated Wrapping System With Nest And Folding Assembly
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Solution Overview
Problem
The manual wrapping and fastening of materials like leather or vinyl onto substrate structures in industries such as automotive and aerospace is labor-intensive, time-consuming, and lacks consistency, despite advancements in manufacturing technology.
Innovation Solution
An automated wrapping system comprising a support with a nest and a material folding assembly that moves between rest and actuated positions to fold and secure the material over the substrate edge, using actuators and a fastening mechanism for efficient and precise attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual wrapping and fastening methods are used, then flexibility and adaptability are maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical wrapping operations with an automated system that uses programmable robotic mechanisms. The system includes a robotic arm with wrapping tools that can automatically apply materials like leather or vinyl to substrates, eliminating the need for manual labor while maintaining wrapping quality through programmable control.
Solution Approach 2:
The automated wrapping system performs the wrapping operation autonomously without continuous human intervention. The robotic system can complete the entire wrapping and fastening process independently, with humans only needing to load materials and retrieve finished products, thereby dramatically improving productivity.
2Device complexity
If manual wrapping methods are used, then equipment complexity is low, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The patent replaces manual wrapping operations with an automated robotic system that uses programmable control to achieve consistent wrapping precision. The system includes sensors and control algorithms that ensure uniform material application and precise fastening, eliminating the variability inherent in manual operations.
Solution Approach 2:
The automated wrapping system incorporates sensors and control mechanisms that provide real-time feedback on the wrapping process. This feedback loop allows the system to detect and correct deviations from the desired wrapping pattern, ensuring consistent precision across all wrapped substrates.
3Device complexity
If manual fastening operations are performed, then device complexity remains low, but labor intensity and cost increase
Solution Approach 1:
The patent replaces manual fastening operations with an automated robotic system that can apply staples, adhesive, or other fastening mechanisms at high speed. The robotic arm is equipped with interchangeable fastening tools that can be programmed to apply the appropriate fastening method based on the substrate and material being wrapped.
Solution Approach 2:
The automated fastening system operates continuously without the interruptions inherent in manual operations. The robotic system can maintain constant fastening speed and can perform multiple fastening operations in sequence without pausing, thereby dramatically increasing overall productivity and reducing labor costs.
Data Source
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AI summary
An automated wrapping system for wrapping a substrate with a material includes a support and a nest mounted to the support that is configured to position the material between an outer portion of the substrate and the nest. The automated wrapping system also includes a material folding assembly positioned adjacent to the nest configured for movement between a rest position and an actuated position, wherein the movement of the material folding system to the actuated position engages and folds the free end portion of the material over the edge of the substrate and onto a part of the inner portion of the substrate while retaining the material against the edge of the substrate. An actuator connected to the material folding assembly moves the material folding assembly between the rest position and the actuated position.