Smoking Cartridge Assembly With Vision-Guided Robotic Alignment
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Solution Overview
Problem
The manufacturing of electronic smoking articles, such as cartridges for aerosol delivery devices, is challenging due to the small and fragile nature of their components, making manual assembly inefficient and costly, and there is a need for an automated system to enhance repeatability and reduce errors.
Innovation Solution
An automated assembly system comprising a supply unit, feeder unit, and assembly units that work together to precisely assemble cartridges, using a rotary member to alternate delivery of components and a robotic arm to insert partially-assembled cartridges into an outer body, with a suction system for precise alignment and insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used for cartridge components, then flexibility and adaptability are maintained, but assembly efficiency and productivity are low
Solution Approach 1:
The patent replaces manual mechanical assembly with an automated robotic system that uses vision guidance and precise positioning mechanisms. The robotic arm with end effector automatically picks up components and assembles them into the cartridge, eliminating manual labor while maintaining high precision through feedback control and alignment features.
2Manufacturing precision
If automated assembly is implemented, then productivity and precision are improved, but device complexity increases
Solution Approach 1:
The patent introduces a vision system as an intermediary between the robotic arm and the components. The vision system captures images, processes component positions and orientations, and provides feedback to the robotic control system. This intermediary enables precise alignment and positioning without requiring complex mechanical positioning mechanisms, thereby managing system complexity while maintaining high manufacturing precision.
Solution Approach 2:
The patent implements a feedback control system where the vision system continuously monitors component positions and the robotic arm's movements. The system compares actual positions with target positions and makes real-time adjustments to ensure precise alignment during assembly. This feedback mechanism maintains high precision while allowing the use of programmable robotic systems rather than overly complex mechanical positioning devices.
3Productivity
If components are handled manually, then adaptability to component variations is maintained, but assembly time and production cost increase
Solution Approach 1:
The patent employs a vision system that performs preliminary identification and positioning of components before the robotic arm begins assembly. The system captures images, processes the component locations and orientations, and pre-calculates the assembly path. This preliminary action allows the robotic arm to execute assembly operations quickly and efficiently without manual intervention for each component, thereby reducing assembly time while maintaining adaptability to component variations.
4Manufacturing precision
If precise alignment mechanisms are added, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical alignment mechanisms with a vision-guided robotic system. Instead of using precision mechanical guides, fixtures, or alignment jigs, the system uses digital image processing and robotic positioning control to achieve precise component alignment. This substitution reduces mechanical complexity while maintaining or improving alignment precision through software-based control and feedback.
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 system enables efficient, precise, and cost-effective assembly of aerosol delivery device cartridges, reducing human error and increasing production efficiency while maintaining high-quality components alignment and assembly.
Implementation Method 1
a suction system for precise alignment and insertion
Data Source
AI summary
The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges may be assembled by coupling a base of the cartridge to a carriage that is transported via a track. The track transports the carriages between various substations at which one or more parts are added to the base. The carriage may be lifted from the track by a lifter mechanism at each substation in order to perform assembly operations on the base. An inspection system may inspect the cartridges at various stages of completion at or between the various substations.