Semiautomatic Connector Pin Swaging Machine
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Solution Overview
Problem
The manual process of securing connector pins to circuit boards in circuit board assemblies is inconsistent and labor-intensive, leading to quality and productivity issues in manufacturing.
Innovation Solution
A semiautomatic machine with a rotating indexer, anvil holder, punch, and vibrators is used to automate the alignment and securement of connector pins, featuring adjustable components for different pin dimensions and vibration control to ensure consistent pressure and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual process is used to secure connector pins to circuit boards, then flexibility in handling different pin types is maintained, but consistency and quality of assembly deteriorate
Solution Approach 1:
The machine divides the assembly process into distinct operational phases: feeding connector pins from a bowl through a vibratory feeder, positioning them on a rotary indexer, and securing them with a punch mechanism. This segmentation allows each component to specialize in one function, achieving consistent results while keeping the overall system manageable through modular design
Solution Approach 2:
The rotary indexer serves multiple functions: it positions connector pins, holds circuit boards, and coordinates the timing of pin insertion. The vibratory feeder also performs both vibration to move pins and feeding to deliver them to the indexer. This multi-functionality reduces the number of separate components needed, addressing the complexity concern
2Productivity
If manual labor is used for each connector pin placement, then adaptability to different pin configurations is maintained, but productivity deteriorates
Solution Approach 1:
The rotary indexer enables continuous operation by rotating to present new circuit board positions to the punch mechanism after each pin is secured. The vibratory feeder continuously supplies connector pins from the bowl without interruption. This continuous action eliminates idle time between operations, significantly increasing productivity while maintaining manageable automation through a single rotary motion
Solution Approach 2:
Connector pins are pre-positioned in a gravity-fed bowl with vibratory assistance before the actual assembly begins. The vibratory feeder prepares pins by orienting and transporting them to the indexer in advance. This preliminary preparation eliminates the need for manual pin handling during the high-speed assembly phase, boosting productivity
3Reliability
If inconsistent pressure is applied during pin insertion, then ease of operation is maintained, but reliability of connector securement deteriorates
Solution Approach 1:
The machine incorporates sensors that detect when a connector pin is properly positioned and when the circuit board is correctly located. This feedback ensures that the punch mechanism applies pressure only at the appropriate moment and to the correct components, guaranteeing reliable securement. The system automatically adjusts based on sensor input, maintaining simplicity of operation while ensuring consistent quality
Solution Approach 2:
Manual pressure control is replaced with a mechanically-driven punch system that uses controlled mechanical force through the rotary indexer mechanism. The consistency of pressure is achieved through the precision mechanics of the indexer rotation and punch positioning, eliminating variability introduced by manual operation while keeping the control system simple through mechanical rather than electronic complexity
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 machine simplifies and expedites the assembly process, ensuring consistent and high-quality securement of connector pins to circuit boards, improving productivity and quality of circuit board assemblies.
Implementation Method 1
various vibrators may be mounted to the machine to encourage movement of the at least one connector pin from the feeding bowl to the track
Implementation Method 2
the punch is pressed against the anvil holder to secure the at least one connector pin to the circuit board. As a result, a top section of the connector pin may be compressed to form a top lip
Data Source
AI summary
A machine that is used to automate the assembly of a circuit board assembly is provided. The machine includes a rotating indexer, at least one anvil holder, a punch, and an activation switch. The at least one anvil holder is carried by the rotating indexer and is configured to receive a connector pin. The anvil holder is rotatable relative to the punch, such that the at least one anvil holder may be aligned with the punch. A circuit board may be located about the connector pin, after which the activation switch may be activated to cause movement of the punch towards the anvil holder. When this occurs, the connector pin is compressed, which causes the connector pin to be secured to the circuit board. More specifically, a top section of the connector pin is compressed to form a top lip, where the circuit board is located between the top lip and a shoulder of the connector pin.