Expandable Ring Mandrel for Precise Pull Wire Laser Welding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Manual assembly of pull wire assemblies is time-consuming, prone to defects, and physically straining for operators, with components requiring precise positioning for reliable laser welding.

Innovation Solution

An automated pull wire assembly machine with a ring holder and gantry system that positions and aligns pull rings and wires for laser welding, featuring a ring mandrel with movable mandrel members and a gantry for three-dimensional positioning, along with a wire placement system, laser weld system, and removal system to automate the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual assembly is used with operator observation through microscope, then precise positioning of components is achieved, but assembly time is excessive (50-75 seconds per assembly) and operator fatigue increases

Engineering Contradiction:

Improvecomponent positioning precisionVSAvoidassembly throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical assembly operations with an automated machine system that includes a ring holder, wire feeder, laser weld system, and control unit. The machine automatically positions the pull ring and pull wire, performs laser welding, and removes the assembled product, eliminating the need for operator manual handling while maintaining precision through automated positioning mechanisms and laser guidance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated machine performs all assembly operations autonomously without continuous operator intervention. The system self-position s components, self-welds using laser, and self-removes finished assemblies, with the control unit coordinating all operations to achieve both precision and high throughput.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual assembly with careful component handling is used, then assembly quality is maintained, but operator physical strain increases and defect risk increases

Engineering Contradiction:

Improveassembly qualityVSAvoidoperator physical comfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If manual removal of assembled product from fixture is performed, then product integrity is maintained, but operator fatigue increases and defect risk increases

Engineering Contradiction:

Improveproduct integrityVSAvoidassembly cycle time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual removal operations with an automated machine system. The machine uses automated mechanisms to release and remove the assembled pull wire assembly from the fixture, eliminating operator physical strain and the risk of manual handling defects while maintaining product integrity through controlled removal processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 assembly process significantly reduces assembly time, minimizes defects, and reduces operator strain, enabling high-quality production with improved throughput and efficient sorting of assembled parts.

Implementation Method 1

The pull wires assemblies are manually assembled relying on the operator carefully handling the components to load the pull ring and the pull wire into a fixture using miniature pliers. The operator observes the assembly process through a microscope. The components need to be precisely positioned to achieve a reliable connection through a laser welding process.

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS20250319547A1Pull ring holder for a pull wire assembly machine

Publication Date: 2025.10.16 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A ring holder for a pull wire assembly machine configured to assemble a pull wire to a pull ring is provided. The ring holder includes a ring mandrel having a first mandrel member and a second mandrel member meeting at a seam. The ring mandrel includes a ring mount 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.