End-of-Arm Tool for In-Process Conductivity Testing
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Solution Overview
Problem
In manufacturing processes, the presence of defective conductive components can render entire products faulty, leading to costly discards, as existing technologies lack a method for real-time conductivity testing during automated production.
Innovation Solution
A system utilizing a robotic arm with an end-of-arm tool equipped with probes to measure electrical resistance of components, comparing the measurements to predetermined thresholds, and discarding defective components while allowing the manufacturing process to continue with conductive ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conductivity testing is performed prior to assembly or after completion, then measurement accuracy is ensured, but manufacturing automation is restricted and productivity is reduced
Solution Approach 1:
The conductivity test is performed preliminarily during the manufacturing process itself, before assembly or completion. The end-of-arm tool conducts resistance measurements on components while they are being manufactured, enabling real-time quality verification without delaying subsequent assembly operations.
Solution Approach 2:
The testing function is merged with the manufacturing process by integrating the end-of-arm tool directly into the robotic system. The probe-based resistance measurement capability is combined with the existing automated handling and assembly operations, allowing both manufacturing and testing to occur within the same automated workflow.
2Productivity
If real-time conductivity testing is implemented during automated manufacturing, then productivity is improved and waste is reduced, but device complexity increases
Solution Approach 1:
The end-of-arm tool serves multiple functions: it performs the standard gripping and handling operations of a robotic end effector while simultaneously conducting conductivity testing through integrated probes. This multi-functionality eliminates the need for separate testing equipment, reducing overall system complexity despite adding real-time testing capability.
Solution Approach 2:
The robotic system tests its own manufactured components using the end-of-arm tool without requiring external testing machinery. The system self-verifies component conductivity during the manufacturing process, eliminating the need for separate dedicated testing systems and reducing overall device complexity.
3Reliability
If defective components are identified and removed in real-time, then product quality is improved and waste is reduced, but measurement precision requirements increase
Solution Approach 1:
The system continuously monitors resistance measurements during manufacturing and provides immediate feedback to the control system. When a component fails the conductivity test, the system automatically identifies and removes the defective component, preventing it from proceeding to assembly. This closed-loop feedback ensures high product quality while using straightforward resistance measurement principles.
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 real-time conductivity testing during automated manufacturing, reducing waste and increasing efficiency by identifying and removing defective components promptly, thus enhancing the automation of manufacturing processes involving conductive components.
Implementation Method 1
The probes can contact a component and measure its electrical resistance
Data Source
AI summary
An inspection assembly, a system, and a method of in-process conductivity testing includes a mechanical end effector with first and second contact pads. The mechanical end effector is configured to move the first and second contact pads into contact with a manufactured part. An electrical potential is applied across the first and second contact pads. A conductivity of the manufactured part is evaluated and a dispositive action determined.