Automated Fluid Exchange Assembly for Insulating Glass Units

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Solution Overview

Problem

The existing methods for assembling insulating glass units (IGUs) are inefficient due to the manual and delicate nature of inserting needles for evacuating atmospheric air and inserting inert gases, which can damage the glass and are time-consuming.

Innovation Solution

A fluid exchanging system comprising an articulating arm with an optical sensor system and a fluid exchanging apparatus that identifies and accurately positions an opening in the IGU, using a probe to confirm clearance and alignment, and a controller to instruct the fluid exchanging head for precise evacuation and fluid dispensing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a needle is manually inserted to evacuate atmospheric air and insert inert gas, then the IGU can be filled with inert gas, but the needle is delicate and easily bent and can scratch the glass

Engineering Contradiction:

Improveneedle durabilityVSAvoidglass damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the manual mechanical needle insertion process with an automated robotic system. The robotic arm precisely positions and inserts the needle, eliminating manual handling that causes bending and damage. The system uses automated control to ensure proper insertion depth and angle, preventing glass scratches while maintaining needle integrity through consistent, controlled operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates sensors that automatically detect the IGU position and spacing, allowing the robotic system to self-adjust its insertion parameters. The needle insertion process is self-regulated through feedback mechanisms that monitor insertion force and depth, preventing excessive force that could bend the needle or damage the glass.

Inventive Principle:

Principle #25Self-service

2Productivity

If manual methods are used for IGU assembly, then flexibility is maintained, but the process is time-consuming and inefficient

Engineering Contradiction:

Improveassembly speedVSAvoidassembly time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The robotic system performs evacuation and inert gas insertion in continuous automated operations without the breaks and repositioning required in manual processes. The system can continuously process multiple IGUs in sequence, maintaining constant productive action. The automated needle insertion and fluid exchange occur without interruption, maximizing assembly throughput and eliminating idle time between operations.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent extracts the time-consuming manual operations from the assembly process and replaces them with automated robotic functions. By taking out the manual needle handling, positioning, and insertion tasks and assigning them to a robotic system, the process eliminates the delays associated with manual dexterity limitations and fatigue, significantly reducing total assembly time while maintaining precision.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If precise positioning is achieved through automated systems, then accuracy improves, but device complexity increases

Engineering Contradiction:

Improveneedle insertion accuracyVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The robotic system is designed as a multi-functional platform that handles positioning, needle insertion, fluid evacuation, and inert gas insertion through a single integrated apparatus. This universal system replaces multiple separate manual operations, achieving high precision through automated control while consolidating complexity into one coordinated system rather than requiring multiple specialized devices.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system introduces a robotic arm as an intermediary between the control system and the needle insertion process. This intermediary provides precise positional control and force management, enabling accurate needle placement without requiring complex direct manipulation mechanisms. The robotic arm acts as a mediator that translates control commands into precise physical actions, simplifying the overall control architecture while maintaining high precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11480010B2Insulating glass unit fluid exchange assembly and method

Publication Date: 2022.10.25 GED INTEGRATED SOLUTIONS INC

AI summary

A fluid exchanging system and method for use in exchanging fluids in insulating glass units (IGUs). The fluid exchanging system includes an articulating arm having a plurality of members and arms to allow movement about multiple axes defined by the articulating arm, an optical sensor system, coupled to the articulating arm, for identifying an opening in a spacer frame of an IGU, and a fluid exchanging apparatus releasably couplable to the articulating arm. The fluid exchanging apparatus also includes a fluid exchanging head for evacuating atmospheric air from the IGU and dispensing fluid into the IGU.