Head Suspension Damper Automated Punching and Affixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing head suspensions result in varying vibration damping effects and decreased productivity due to manual handling of dampers, which affects the accuracy and consistency of damper placement on head suspensions.
Innovation Solution
A method and apparatus that automate the process of punching and affixing dampers to head suspensions using a hollow punch and pusher, ensuring precise positioning and adherence to objective parts, including discontinuous sections, to achieve uniform vibration damping and improved productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual operation is used to pick up and affix dampers to head suspensions, then flexibility in handling is maintained, but the vibration damping effect varies among head suspensions and productivity deteriorates
Solution Approach 1:
The damper is designed with a self-adhesive structure where the adhesive layer is exposed after punching, allowing the damper to automatically adhere to the head suspension objective part without manual intervention. The punch tool itself serves as the positioning and application mechanism, eliminating the need for separate handling steps.
Solution Approach 2:
The punching and affixing operations are merged into a single integrated process. The hollow punch both cuts out the damper from the material and directly positions it onto the head suspension, combining multiple functions into one tool and operation sequence.
2Measurement precision
If manual picking with tweezers is used, then precise placement can be attempted, but time is lost and dampers may be lost or misplaced
Solution Approach 1:
The system eliminates the need for manual picking by designing the punch to automatically hold, position, and release the damper in the correct location. The adhesive exposure mechanism ensures the damper self-anchors upon contact with the objective part.
Solution Approach 2:
The hollow punch serves as an intermediary tool that temporarily holds the damper during transfer and positioning, then releases it precisely at the target location. This mediator ensures accurate placement without requiring manual dexterity.
3Productivity
If automated punching and affixing is implemented, then productivity and uniformity are improved, but device complexity increases
Solution Approach 1:
The punching tool and positioning mechanism are merged into a single hollow punch component. The same tool that cuts the damper also holds and positions it, eliminating the need for separate picking tools, positioning jigs, and affixing mechanisms.
Solution Approach 2:
The hollow punch performs multiple functions: it punches out the damper from material, holds the punched damper in its cavity, transports it to the objective part, positions it accurately, and releases it for affixing. This multi-functional tool reduces overall system complexity.
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 ensures consistent vibration damping across head suspensions, prevents damper loss, and enhances manufacturing efficiency by simplifying handling and positioning, leading to improved accuracy and yield in head suspension production.
Implementation Method 1
the viscoelastic layer of the damper is interposed between a head suspension and the retaining layer. When the head suspension vibrates and deforms, the viscoelastic layer deforms accordingly, to create frictional motion among viscoelastic molecules
Implementation Method 2
create frictional motion among viscoelastic molecules. This frictional motion converts vibration energy into thermal energy
Implementation Method 3
the adhesive face of the damper is affixed to the objective part
Data Source
AI summary
A method of manufacturing a head suspension includes a punching process, a positioning process, and an affixing process. An objective part on the head suspension to which a damper 73 is affixed includes a discontinuous section 72. The punching process punches a damper material into the damper 73 whose shape corresponds to the shape of the objective part excluding the discontinuous section 72. The positioning process positions the damper 73 to the objective part so that the damper 73 avoids and surrounds the discontinuous section 72, and the affixing process affixes the damper 73 to the objective part. The method secures a uniform damping effect among manufactured head suspensions and improves the yield of dampers and head suspensions without deteriorating the functions and performances of the head suspensions.