Cartridge Assembly Line With Vision Alignment for Fragile Components
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Solution Overview
Problem
Existing electronic smoking articles are difficult to manufacture due to their small and fragile components, necessitating improved systems and methods for assembly.
Innovation Solution
A system and method for assembling aerosol delivery device cartridges, featuring a carriage with an engagement head and track that aligns and assembles components via an interference fit, utilizing imaging for rotational orientation detection and storing identification and status information, with features like electrostatic dissipative material and ferromagnetic components for precise assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional assembly methods are used for electronic smoking articles, then the manufacturing process is simple, but the components are difficult to assemble due to their small size and fragility
Solution Approach 1:
The patent replaces manual mechanical assembly with an automated assembly system that uses robotic end effectors to precisely position and attach components. The system incorporates vision guidance and automated control to handle the small, fragile components without manual intervention, thereby improving ease of manufacture while maintaining component integrity through controlled, repeatable operations.
Solution Approach 2:
The patent employs adjustable end effectors with controllable gripping forces and positioning precision. By dynamically adjusting parameters such as grip strength, positioning accuracy, and attachment force, the system can adapt to different component sizes and fragilities, enabling easy assembly while preventing damage to delicate parts.
2Manufacturing precision
If automated assembly systems are implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent designs a modular assembly system where robotic end effectors can perform multiple functions (grasping, positioning, attaching, and inspecting components) through programmable control. The vision system and robotic manipulators are configured to handle various component types with a single setup, achieving high manufacturing precision without proportionally increasing system complexity through standardized, multi-purpose equipment.
Solution Approach 2:
The patent uses vision systems to create digital models or copies of component positions and orientations, which are then used to guide robotic manipulators for precise assembly. This optical copying approach enables high positioning accuracy while keeping the physical mechanical guidance structures relatively simple, as the complexity is managed through software processing of visual data rather than complex mechanical linkages.
3Productivity
If manual assembly is used, then device complexity remains low, but productivity decreases
Solution Approach 1:
The patent divides the assembly process into discrete, automated stages: component feeding, vision inspection, robotic grasping, positioning, and attachment. Each stage is handled by specialized modules that can operate in parallel or sequence, significantly increasing productivity compared to manual assembly. The segmented approach manages system complexity by breaking down the overall process into manageable, independently controlled segments.
Solution Approach 2:
The patent implements preliminary actions such as pre-positioning components on feeders, pre-inspecting parts with vision systems, and pre-programming robotic trajectories before actual assembly begins. These preliminary automated actions prepare the system for rapid execution of the main assembly task, boosting productivity while the complexity is confined to the setup and control systems rather than the core assembly operation.
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
Facilitates efficient and precise assembly of aerosol delivery device cartridges, ensuring proper alignment and integration of components, enhancing manufacturing efficiency and reducing component damage.
Implementation Method 1
an engagement head defining a plurality of sections configured to engage the internal surface of the attachment end of the base via an interference fit
Data Source
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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.