Stamped Contact Cutter With Comb Alignment for Miscut Reduction
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Solution Overview
Problem
Conventional bandoleers for manufacturing processes are not sufficiently automated, are difficult to load, and are prone to miscutting and other critical process flaws, leading to wasted robotic time, manufacturing downtime, and material waste.
Innovation Solution
An automated contact cutter system that includes a contact reel holder, an inlet roller, a turn roller, a receiving roller, and a comb, all mechanically connected by a common motor drive belt to a drive motor, which enables automated loading, cutting, and delivery of stamped contacts for robotic pick and insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional bandoleers are used with manual loading and advancing, then device complexity is reduced, but automation extent is insufficient and manufacturing precision deteriorates due to miscutting and process flaws
Solution Approach 1:
The patent combines multiple functions (loading, advancing, cutting, and combing) into a single integrated apparatus. The bandoleer loader, cutter, and comb are merged into one device that operates automatically, eliminating the need for separate manual operations while managing complexity through functional integration.
Solution Approach 2:
The cutting apparatus serves multiple functions: it loads the bandoleer onto the reel, advances the material through rollers, positions it with a comb, cuts the contacts, and delivers them to the robot. This multi-functionality increases automation while consolidating operations into a single system.
2Productivity
If manual advancing and monitoring of bandoleer is performed, then ease of operation is maintained, but productivity is reduced due to constant intervention and manufacturing downtime
Solution Approach 1:
The apparatus is designed to load and advance the bandoleer automatically without requiring constant manual intervention. The system serves itself by mechanically feeding the material through the cutting mechanism, thereby increasing productivity while reducing the operational burden.
Solution Approach 2:
The bandoleer is pre-loaded onto the reel in advance, and the apparatus automatically advances it through the cutting process. This preliminary preparation eliminates the need for continuous manual reloading and monitoring during operation, improving productivity.
3Manufacturing precision
If conventional cutting systems are used, then device complexity is lower, but manufacturing precision deteriorates due to miscutting, overstretching, breakage, and misalignment
Solution Approach 1:
The comb acts as an intermediary element that positions and aligns the bandoleer and cut contacts before they reach the cutter and robot. This intermediate positioning step ensures precise alignment and reduces misalignment errors, improving manufacturing precision.
Solution Approach 2:
The cutting process is segmented into distinct stages: loading the bandoleer, advancing it through controlled rollers, positioning with the comb, cutting, and delivering to the robot. This segmentation allows each stage to be optimized for precision while managing overall system complexity.
4Productivity
If automated cutting is implemented, then productivity increases, but device complexity increases due to additional mechanical components
Solution Approach 1:
Multiple mechanical functions are merged into a single apparatus: the loader, rollers, comb, and cutter are integrated into one automated system. This consolidation increases productivity by eliminating manual operations while managing complexity through unified design.
Solution Approach 2:
The apparatus performs multiple operations automatically: loading the bandoleer, advancing material, positioning contacts, cutting, and delivering to the robot. This multi-functionality increases productivity while consolidating operations into a single device.
Data Source
AI summary
An apparatus, system and method for providing an automated contact cutter. The contact cutter includes a contact reel holder for holding therein a bandoleer comprising a plurality of stamped contacts; at least an inlet roller comprising an inlet pin, a turn roller, and a receiving roller mechanically connected by at least one motor drive belt to a drive motor, wherein the inlet roller is capable of receiving an end portion of the bandoleer onto the inlet pin for loading; a cutter between the turn roller and the receiving roller that is capable of cutting ones of the stamped contacts from the bandoleer for picking by a pick and place robot; and a comb capable of combing at least the bandoleer and cut and partially cut ones of the stamped contacts.