Automated Hook Fastening Strip Feeder for Mold Assembly

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Solution Overview

Problem

In the manufacturing of automobile seat foam buns, the manual process of selecting and placing hook fastening strips of varying lengths into molds is inefficient, requiring operators to frequently move between a parts rack and the assembly line to accommodate different trench lengths and curvatures.

Innovation Solution

An automated system that includes sensors to detect mold positions and required strip lengths, a controller, stepper motor, and cutter to cut hook fastening tape to precise lengths, and a feeder assembly with a spool change unit, accumulator, and cutting and discharge unit to supply the correct number and length of strips to molds moving along a mold assembly line.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual operators select and place hook fastening strips from a parts rack, then flexibility in accommodating different trench lengths and curvatures is achieved, but labor efficiency decreases and production time increases

Engineering Contradiction:

Improveadaptability to different trench lengths and curvaturesVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system enables self-service automation where the feeder assembly automatically detects mold requirements through sensors, selects appropriate hook fastening strip lengths, and delivers them to the correct molds without human intervention. The controller autonomously manages the entire process from detection to delivery, resolving the contradiction by eliminating manual labor while maintaining adaptability through automated sensing and selection mechanisms.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical system of operators selecting and placing strips with an automated feeder assembly that uses sensors, controllers, and automated delivery mechanisms. This substitution maintains the ability to accommodate different trench configurations while dramatically improving production efficiency by eliminating repetitive manual movements between the parts rack and assembly line.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If operators frequently move between the parts rack and assembly line, then correct strip selection is ensured, but time loss increases and operational complexity increases

Engineering Contradiction:

Improveaccuracy of strip selectionVSAvoidtime lost in movement and selection

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs preliminary action by pre-positioning hook fastening strips of various lengths in the feeder assembly and using sensors to detect mold requirements before the mold reaches the delivery point. The controller pre-calculates and prepares the correct strip for delivery, eliminating the time loss associated with operators moving back and forth to select strips while ensuring accurate selection through automated detection and selection mechanisms.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The feeder assembly acts as an intermediary between the strip storage and the mold assembly line. It receives strip length requirements from sensors detecting mold characteristics, automatically selects and prepares the appropriate strips, and delivers them to the correct molds. This intermediary system eliminates the need for operators to physically move between storage and assembly areas while maintaining precise strip selection through automated sensing and control.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If pre-cut hook fastening strips are stored in a parts rack, then various lengths are available, but storage space is required and waste from packaging increases

Engineering Contradiction:

Improveavailability of various strip lengthsVSAvoidpackaging waste and storage space

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The system applies segmentation by providing different length hooks directly at the point of use through the feeder assembly, eliminating the need for centralized storage of pre-cut strips in various packaging. The feeder assembly segments the continuous strip material into required lengths on-demand, maintaining adaptability to different mold requirements while eliminating packaging waste and reducing storage space requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system implements discarding and recovering by using continuous hook fastening tape that is cut to length at the point of use rather than storing pre-cut strips in packaging. The unused portions of the continuous tape are discarded without packaging waste, and the system recovers efficiency by eliminating the storage and handling of packaged pre-cut strips. This approach maintains availability of various lengths through automated cutting while eliminating packaging material waste.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS10569447B2Systems and methods of feeding hook fastening elements

Publication Date: 2020.02.25 YKK CORP

AI summary

Systems and methods for introducing hook fastening elements into a mold traveling along a mold assembly line are disclosed. The system can be configured to cut hook fastening tape into strips having a predetermined length based on information received from the mold assembly line, and to drop the cut strips directly into the mold at the appropriate intervals as the mold travels along the mold assembly line. Also disclosed is a system for facilitating the continuous feeding of hook fastening tape through the system.