CNC Component Delivery Segmentation for Tool Synchronization
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Solution Overview
Problem
Conventional continuous motion assembly systems are limited in output due to the speed at which components can be delivered and handed off to rotating tools, leading to increased costs and equipment failures from requiring multiple tools and high-speed component handling, which can damage components.
Innovation Solution
An automated system using computer numerical controlled drives for component delivery, allowing independent selection of delivery time, position, speed, acceleration, and trajectory in programmable stages, enabling precise control and synchronization of component delivery to stationary or moving tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dial speed is increased to increase output, then productivity increases, but the speed at which components are handed over to the dial must increase as well, which is limited by the practical maximum speed of conventional component delivery devices
Solution Approach 1:
The component delivery process is divided into multiple independently programmable stages: loading stage, separating stage, accelerating stage, and delivery stage. Each stage can be optimized and controlled independently, allowing the component to be accelerated gradually through multiple phases rather than a single high-speed transfer, thereby resolving the contradiction between increasing output and maintaining reliable component delivery speed.
2Productivity
If the number of tools on a dial is increased to increase output, then productivity increases, but the costs and likelihood of equipment failure increase
Solution Approach 1:
The invention employs a single multi-functional tool on the dial that can perform multiple operations or process different components sequentially. This universal tool replaces the need for multiple specialized tools, thereby maintaining high productivity while reducing equipment complexity, cost, and failure probability associated with having multiple tools.
3Productivity
If the number of tools on a dial is increased to increase output, then productivity increases, but the diameter of the dial increases, resulting in a larger machine occupying greater floor space
Solution Approach 1:
By implementing a single universal tool that can perform multiple functions or process various components, the dial diameter can be kept small while still achieving high output. This eliminates the need to increase the dial size to accommodate multiple tools, thereby maintaining compact machine dimensions and reducing floor space occupation.
4Productivity
If the dial speed increases, then productivity increases, but component damage may occur due to high-speed handling
Solution Approach 1:
The component acceleration and delivery process is segmented into multiple controlled stages with independently programmable parameters. This allows gradual acceleration and precise control at each stage, preventing sudden high-speed impacts that could damage components while still achieving high overall throughput and productivity.
Solution Approach 2:
The invention employs dynamic control of component delivery parameters, where timing, position, speed, velocity, and acceleration are independently adjustable for each stage. This dynamic adaptation allows the system to optimize delivery conditions for different component types and operational requirements, preventing damage while maintaining high productivity.
Data Source
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AI summary
The invention relates to an automated method of assembling or processing components using computer numerical controlled drives to decouple the stages of delivering components to a tool, into a series of separately programmable stages, namely, a component loading stage, a component separating stage, an accelerating stage and a delivery stage, wherein the timing, position, speed, velocity, and acceleration of each component during each stage is selected through programming of the computer numerical controls.