Dummy Component for Flexible Circuit Slot Detection
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Solution Overview
Problem
The FPC insertion process is not mechanized or automated due to difficulties in contact search and long takt time, as FPCs curve and undergo plastic deformation when attempting to use force sensors for slot positioning, and slow pushing speeds are required to avoid damage.
Innovation Solution
A component insertion device and method using a robot with a gripper, a dummy component, and a force sensor to perform compliance control for initial slot recognition, followed by position control for precise insertion of the workpiece component, allowing for faster and more accurate insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a force sensor is used on the robot to search for the slot position through contact reaction force, then the slot position can be detected, but the FPC curves and undergoes great plastic deformation making it difficult to search the position accurately
Solution Approach 1:
The patent introduces a dummy component as an intermediary object that performs the contact search operation instead of the actual FPC. The dummy component has the same external shape as the FPC but is made of a material that does not deform easily. This allows the force sensor to detect slot position through contact reaction force without causing plastic deformation to the real FPC, thus resolving the contradiction between measurement precision and manufacturing precision.
2Reliability
If the FPC is pushed slowly through compliance control to avoid damage, then FPC damage is avoided, but the insertion time becomes very long (about 150 seconds per piece)
Solution Approach 1:
The patent performs the contact search and slot position detection using the dummy component before the actual FPC insertion. By completing the positioning operation in advance with the dummy component, the real FPC can be inserted directly to the detected position without requiring slow compliance control, thus significantly reducing insertion time while avoiding FPC damage.
Solution Approach 2:
The dummy component serves as a mediator that absorbs the compliance control operations. All the slow, careful positioning movements are performed on the dummy component, allowing the actual FPC to be inserted quickly and accurately without undergoing damaging compliance control procedures.
3Device complexity
If the FPC is gripped and inserted directly without a dummy component, then the process is simpler, but contact search causes FPC deformation and plastic damage
Solution Approach 1:
The patent creates a copy of the FPC in the form of a dummy component that has the same external shape and insertion characteristics. This copy is used for the contact search operation, allowing the system to learn the slot position without deforming the original FPC. The dummy component is mounted on the gripper alongside the FPC, enabling the simple gripping operation to proceed without damage.
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
Enables automatic and efficient insertion of flexible workpiece components into slots or holes, reducing insertion time and minimizing damage, with the dummy component facilitating quick slot recognition and the workpiece component being inserted accurately based on recognized positions.
Implementation Method 1
a force sensor capable of detecting, through the gripper, a contact reaction force received by the dummy component from the surrounding of the slot or the hole of the receiving portion
Data Source
AI summary
A component insertion device including a robot and a control portion is provided. The control portion is configured to control the operation of the robot. The robot includes a gripper, a dummy component and a force sensor. The gripper is configured for gripping a workpiece component. The dummy component is mounted protruding outward on a location in the gripper and away from the gripped workpiece component. The dummy component has a corresponding part with the same shape as that of a specific part of the workpiece component and exhibits rigidity. The force sensor is configured for detecting, through the gripper, a contact reaction force received by the dummy component from the surrounding of a slot or hole of a receiving portion by which the specific part of the workpiece comment is to be inserted via using the device. Component insertion method and program of using the device are also provided.