Automated Endoscope Steering Wire Tensioning
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Solution Overview
Problem
The manufacturing of endoscopes, particularly single-use endoscopes, faces challenges related to cost, operator safety, and the quality of steering wire tensioning, which affects the bending performance and feel of the endoscope.
Innovation Solution
A method and system for automating the wire tensioning process in endoscope manufacturing, involving a machine that secures a subassembly of the endoscope, tensions the steering wires, senses the tension, and crimps the wire ends to maintain the tension, thereby improving consistency and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual wire tensioning is performed to achieve proper bending performance, then bending quality is improved, but production cost and time increase
Solution Approach 1:
The patent replaces manual mechanical tensioning operations with an automated tensioning machine that applies controlled forces to the steering wires. The machine uses mechanical actuators to tension the wires to specified values while sensors monitor the tension in real-time, eliminating the need for operator skill and manual adjustment while maintaining consistent bending performance quality.
Solution Approach 2:
The tensioning machine incorporates sensors that automatically monitor wire tension and provide feedback to the control system. When tension reaches the predetermined target value, the system automatically stops tensioning and triggers the crimping operation, eliminating the need for continuous operator intervention and ensuring consistent results without requiring skilled manual judgment.
2Reliability
If steering wires are pre-tensioned to remove slack, then bending performance is improved, but friction increases and construction is strained
Solution Approach 1:
The patent employs sensors that continuously monitor the tension in each steering wire during the tensioning process. The sensor signals are fed back to the control system, which compares the measured tension against the predetermined target value. When the target tension is reached, the control system automatically stops further tensioning, ensuring wires are tensioned to the optimal level without excessive force that would increase friction or strain the construction.
Solution Approach 2:
The system allows for programmable tension parameters to be set for different wire positions and configurations. The control system adjusts the tensioning force parameters based on the specific endoscope design requirements, applying different target tension values to different wires as needed. This optimized parameter selection ensures sufficient tension to remove slack while avoiding excessive tension that would increase friction and strain.
3Device complexity
If operator performs both securement and tensioning, then process simplicity is maintained, but operator safety and quality consistency deteriorate
Solution Approach 1:
The patent divides the manufacturing process into distinct functional modules: a securement station where the endoscope is secured to the machine, and a tensioning station where the automated machine performs wire tensioning. This segmentation separates the operator's role (securement) from the automated machine's role (tensioning), eliminating operator exposure to safety risks during tensioning while ensuring consistent quality through automated control.
Solution Approach 2:
The automated tensioning machine acts as an intermediary between the operator and the steering wires. The operator secures the endoscope to the machine, and then the machine's automated system performs the tensioning operation using controlled mechanical actuators and sensors. This intermediary system eliminates direct operator contact with the tensioning process, improving safety while maintaining quality consistency through automated control.
Data Source
AI summary
A method for tensioning endoscope steering wires includes providing a semi-assembled endoscope including a handle and an insertion cord having a distal bending section connected to a first steering wire and a second steering wire, each steering wire having a first wire end being connected at the bending section at a distal end thereof and arranged in a respective wire pipe extending from a proximal end of the bending section to the handle, each steering wire having a proximal end extending further out of the wire pipe, providing a wire tensioner comprising a first and second wire gripper, providing a wire fastener, securing the semi-assembled endoscope relative to the wire tensioner and wire fastener, arranging each wire gripper to grip a respective one of the steering wires, activating the wire tensioner to tension the steering wires, and activating the wire fastener to fixate the steering wires in the tensioned state.