Expandable Ring Mandrel for Precise Pull Wire Assembly
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Solution Overview
Problem
Manual assembly of pull wire assemblies is time-consuming, physically straining, and prone to defects, with operators needing to handle small components under a microscope for precise laser welding.
Innovation Solution
An automated pull wire assembly machine with a ring holder and integrated systems for precise positioning and laser welding of pull wires to pull rings, featuring a ring mandrel, wire placement, laser weld, and removal systems, controlled by a vision system and control system for quality assurance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual assembly is used, then operator flexibility and component handling capability are maintained, but assembly time increases significantly and operator fatigue increases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated machine system that uses mechanical components (mandrels, fixtures, positioning devices) to perform wire insertion, ring positioning, and assembly operations. This substitution maintains precise component handling while dramatically reducing assembly time from 50-75 seconds per assembly to automated cycle times, eliminating operator fatigue while preserving operational capability.
2Ease of operation
If manual positioning is used, then operator judgment and adjustment capability are preserved, but manufacturing precision and alignment consistency deteriorate
Solution Approach 1:
The patent replaces manual positioning and judgment operations with automated positioning systems featuring fixed fixtures, precision mandrels, and alignment devices. These mechanical systems provide repeatable, consistent positioning for wire insertion and ring alignment, eliminating variability in alignment precision while removing the need for operator judgment during the positioning process.
Solution Approach 2:
The patent establishes fixed geometric parameters through precision-machined fixtures and mandrels with specific dimensions, tolerances, and orientations. These predetermined parameters ensure consistent alignment and positioning for laser welding operations, replacing operator judgment with controlled, repeatable physical constraints that guarantee manufacturing precision.
3Adaptability or versatility
If manual assembly operations are performed, then adaptability to component variations is maintained, but reliability and defect rates worsen due to fatigue
Solution Approach 1:
The patent replaces manual assembly operations with an automated machine system that performs wire insertion, ring positioning, and securing operations consistently. This eliminates fatigue-related defects and improves reliability by maintaining uniform application of forces, torques, and positioning throughout production, while the system's design accommodates component variations through adjustable fixtures and tolerance-compensating mechanisms.
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
The automated process significantly reduces assembly time, minimizes operator fatigue, and enhances production quality by ensuring precise alignment and consistent welds, with improved throughput and reduced defect rates.
Implementation Method 1
The pull wires are laser welded to the pull ring in the slot
Data Source
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AI summary
A ring holder (306) for a pull wire assembly machine (100) configured to assemble a pull wire (20) to a pull ring (30) is provided. The ring holder includes a ring mandrel (380) having a first mandrel member (390) and a second mandrel (392) member meeting at a seam (391). The ring mandrel includes a ring mount (382) at a front of the ring mandrel configured to hold the pull ring. The first and second mandrel members are movable relative to each other to expand a size of the ring mount to hold the pull ring on the ring mount and the first and second mandrel members being movable relative to each other to reduce a size of the ring mount to release the pull ring from the ring mount.