Fastener Dispensing Device with Stepper Motor Control
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Solution Overview
Problem
Existing plastic fastener dispensing devices are limited by their single stroke operation, slow stroke speed, inefficiency, voltage dependency, lack of computerized monitoring, and inability to dispense multiple fasteners rapidly, which hampers productivity and versatility.
Innovation Solution
A device with a stepper motor and electronic controller that allows for multiple fasteners to be dispensed in a single actuation, adjustable stroke speed, energy efficiency, compatibility with various voltages, and computerized monitoring, featuring a head assembly with needles and a feed mechanism for precise fastener dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single stroke operation is used in existing dispensing devices, then the device structure remains simple, but the productivity is limited and multiple fasteners cannot be dispensed rapidly
Solution Approach 1:
The device divides the dispensing operation into multiple independent stroke cycles that can be executed sequentially within a single actuation. The head assembly can perform multiple strokes (e.g., first stroke, second stroke, third stroke) by segmenting the dispensing action, allowing multiple fasteners to be dispensed without requiring multiple separate actuations, thus improving productivity while maintaining manageable structural complexity
Solution Approach 2:
The device loads multiple fasteners into the head assembly in advance during a loading phase, so that when actuation occurs, multiple fasteners are ready for immediate dispensing. This preliminary loading of multiple fasteners enables rapid sequential dispensing without delay, resolving the contradiction between simple operation and high productivity
2Adaptability or versatility
If a fixed stroke speed is used in existing devices, then the mechanism is simple, but the adaptability to different materials and applications is reduced
Solution Approach 1:
The device transitions from a fixed stroke speed to a variable stroke speed mechanism where the actuation speed can be dynamically adjusted based on material thickness, fastener type, and application requirements. This dynamic control allows the same device to adapt to different dispensing scenarios without requiring multiple specialized devices, improving versatility while adding controllable complexity
Solution Approach 2:
The device enables changing operational parameters such as stroke speed, actuation force, and feeding rate to match different application requirements. By allowing parameter adjustment rather than fixed operation, the device becomes versatile for various materials and fastener types while maintaining a single unified mechanism structure
3Use of energy by moving object
If induction motor is used in existing devices, then the dispensing operation can be continuous, but energy efficiency is poor and voltage dependency limits portability
Solution Approach 1:
The device replaces the induction motor with a DC motor driven by rechargeable batteries, substituting the continuous AC power requirement with portable battery power. This substitution improves energy efficiency by eliminating continuous power consumption and enables portability, while the battery system can be recharged to restore productivity capability
Solution Approach 2:
The device changes the power source parameter from AC induction motor to DC battery system, allowing operation in environments without continuous electrical power. This parameter change improves energy efficiency and portability while maintaining the ability to perform dispensing operations continuously until battery depletion, resolving the contradiction between energy efficiency and continuous operation
4Loss of information
If stand alone operation is used in existing devices, then the device structure is simple, but the lack of computerized monitoring reduces productivity tracking and process control
Solution Approach 1:
The device incorporates computerized monitoring and communication capabilities that provide feedback on dispensing operations, productivity metrics, and maintenance status. This feedback system enables real-time tracking and process control while the wireless communication architecture allows information transfer without significant complexity addition to the core dispensing mechanism
Data Source
AI summary
A device for dispensing individual plastic fasteners from a continuous supply of 0.1875 inch pitch ladder stock includes a head assembly that is designed to receive the supply of ladder stock, sever an individual fastener from the supply ladder stock and eject the individual fastener during a single stroke of its actuation cycle. The device also includes a stepper motor for driving the head assembly through its actuation cycle, a DC power switching supply for regulating the power supplied to the stepper motor from an AC input power source, and a controller for collecting historical data relating to usage of the device and for regulating operation of the stepper motor. The controller is programmed to enable certain operational characteristics, such as stroke speed and mode, to be regulated through a user interface which includes a screen display and a plurality of control buttons.