Filter Canister Assembly Tracking with Serial Number Database
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Solution Overview
Problem
There is no existing system to automatically manufacture filter canisters while tracking component parts and quality assurance test results, leading to a lack of traceability and certification in the manufacturing process.
Innovation Solution
A computer-based system is implemented for filter canister assembly lines to automatically input component information and quality assurance test results, assigning a unique serial number to each canister and recording component lot numbers, activated charcoal weight, and test results in a database, ensuring traceability and certification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated assembly line is used for manufacturing filter canisters, then productivity is improved, but traceability of component parts and quality assurance results is lost
Solution Approach 1:
The patent divides the manufacturing tracking system into discrete segments: individual component lot numbers are tracked separately, each quality test is recorded independently, and final assembly information is segmented by serial number. This segmentation allows automated high-speed manufacturing while maintaining complete traceability of each component and test result through database recording.
Solution Approach 2:
The patent introduces a computerized database as an intermediary between the automated assembly line and quality tracking. This database receives component lot number information from various sources, records quality assurance test results, and links them to individual serial numbers. The intermediary system enables automated manufacturing while preserving complete traceability without requiring manual intervention at each step.
2Reliability
If individual quality testing of each filter canister is implemented, then reliability is improved, but loss of time increases due to manual recording
Solution Approach 1:
The patent implements a self-service quality tracking system where the automated assembly line and testing equipment directly input data into the computerized database without manual intervention. The system automatically captures component lot numbers, records quality test results, and associates them with serial numbers. This self-service approach maintains comprehensive quality assurance while eliminating time-consuming manual recording operations.
Solution Approach 2:
The patent replaces manual mechanical recording processes with automated electronic data capture and storage. Instead of operators manually writing down test results and component information, the system uses computerized interfaces to automatically record and store data in a database, significantly reducing the time required for quality assurance documentation while maintaining or improving reliability.
3Manufacturing precision
If comprehensive tracking system is implemented for each component and test result, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs a universal computerized database system that handles multiple functions: tracking component lot numbers from various sources, recording different types of quality test results, managing serial number assignment, and providing traceability reporting. This multi-functional universal system achieves comprehensive manufacturing precision while avoiding the complexity of separate specialized systems for each tracking function.
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
This system enables efficient tracking and quality control of each filter canister, allowing for identification of issues and facilitating recalls, while providing trend analysis for preventive maintenance, thus enhancing the manufacturing process.
Implementation Method 1
The body, lower retainer element, and lower fines filter are ultrasonically welded together
Implementation Method 2
a small amount of liquid urethane is squirt into the container and a spin seal process seals the HEPA filter in place
Data Source
AI summary
An assembly line for manufacturing filter canisters is disclosed. The method for assembling filter canisters provides a unique serial number for each canister and a database that associates the component lot numbers, activated charcoal weight, and quality assurance test results with the serial number for the filter canister. The manufacturing method can be adapted for assembly of canisters with activated charcoal and an aerosol HEPA filter, canisters with activated charcoal only, and canisters with an aerosol HEPA filter only. Some embodiments can also enable different testing conditions and specifications, activated charcoal loading requirements, labeling specifications, and packaging requirements.