Embedded Conductor Substrate With Robotic Connector Alignment
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Solution Overview
Problem
Existing methods for manufacturing assemblies with embedded conductors lack precision and automation, requiring human intervention for connector placement and assembly, which is inefficient and prone to errors.
Innovation Solution
An automated additive manufacturing process, such as 3D printing, is used to create a substrate with embedded conductors, featuring precise apertures and location features that allow for robotic assembly and placement of connectors, enabling precise location and arrangement of conductors within the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated additive manufacturing is used to create substrate with embedded conductors, then manufacturing precision and automation are improved, but device complexity increases
Solution Approach 1:
The manufacturing apparatus is divided into separate functional modules: a 3D printing system for substrate formation, a separate robotic arm for conductor placement, and an integrated control system. This segmentation allows each component to be optimized independently while maintaining overall system precision.
Solution Approach 2:
An integrated control system acts as an intermediary between the 3D printing apparatus and robotic conductor placement system. This mediator coordinates the operations of both subsystems, ensuring precise synchronization and positioning without requiring direct complex integration between the printing and robotic systems.
2Productivity
If human intervention is used for connector placement and assembly, then ease of operation is maintained, but productivity and reliability deteriorate
Solution Approach 1:
The system employs self-aligning features where the substrate includes predefined aperture locations and guide structures that automatically position connectors during robotic placement. This self-service mechanism eliminates the need for complex manual alignment procedures while maintaining operational simplicity.
Solution Approach 2:
Manual mechanical assembly operations are replaced with automated robotic systems equipped with vision guidance and force feedback. The robotic system uses programmed sequences and automated tool changing to perform connector placement, achieving both high productivity and ease of operation through programmable automation rather than manual dexterity.
3Extent of automation
If traditional manufacturing methods are used, then device complexity is reduced, but manufacturing precision and automation level worsen
Solution Approach 1:
The 3D printing apparatus is designed with multi-functionality, serving both as a substrate fabrication tool and as a positioning reference system for conductor placement. The same printing system that creates the substrate also defines the precise locations of apertures and guide features, eliminating the need for separate positioning fixtures and reducing overall system complexity.
Solution Approach 2:
The substrate is pre-manufactured with embedded location features, aperture positions, and guide structures using additive manufacturing. These preliminary actions establish the precise geometric framework before conductor placement begins, allowing the robotic system to simply follow pre-defined paths without requiring complex real-time calculation or positioning systems.
Data Source
AI summary
An apparatus includes an extruding device configured to dispense a dielectric material though an orifice, a wire feed device configured to feed a conductive wire through the orifice, and a cutting device configured to sever the wire. It also includes an electronic controller configured to control the extruding device, the wire feed device, and the cutting device. The electronic controller commands the extruding device to dispense the dielectric material though the orifice, the wire feed device to feed the wire through the orifice, and the cutting device to sever the wire, thereby forming a dielectric substrate encasing a plurality of wires. The electronic controller further commands the extruding device to form an opening defined in the substrate in which plurality of electrically conductive wires is exposed and a location feature on the substrate located with a positional tolerance less than or equal to 1 mm relative to the opening.