Jig for Assembling Foldable Position Sensor Substrates
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Solution Overview
Problem
The assembly of triple-axis position sensors (TAPS) with foldable substrates is complex and time-consuming, requiring manual or robotic operation to fold and fasten multiple facets of a flexible printed circuit board around a solid polyhedron, which increases production costs and reduces efficiency.
Innovation Solution
A jig system comprising a base with tracks and movable blocks that fold and fasten facets of a substrate to a solid polyhedron, allowing for automated alignment and coupling of edges, reducing manual intervention and improving assembly quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or robotic operation is used to fold and fasten multiple facets of a flexible printed circuit board around a solid polyhedron, then the position sensor can be assembled, but the assembly process becomes complex and time-consuming
Solution Approach 1:
A jig is introduced as an intermediary device to assist in assembling the position sensor. The jig includes a base with tracks and movable blocks that guide the folding of substrate facets around the polyhedron, simplifying the complex manual or robotic operations into a more straightforward process
Solution Approach 2:
The assembly process is segmented into discrete steps facilitated by the jig's movable blocks, which can be positioned at different locations along the tracks to fold and fasten individual facets sequentially, making the overall complex process more manageable and efficient
2Ease of manufacture
If manual or robotic operation is used to fold and fasten multiple facets, then the position sensor can be assembled, but production costs increase
Solution Approach 1:
The jig serves as a cost-effective intermediary tool that reduces the need for expensive robotic systems while maintaining assembly efficiency. The simple mechanical structure of the jig with movable blocks provides the necessary guidance without the high cost of automation
Solution Approach 2:
The jig appears to be a simple, inexpensive tool compared to robotic systems, potentially designed for single-use or limited-use scenarios where the cost of the jig is justified by the reduction in assembly time and labor costs
3Manufacturing precision
If conventional bending equipment is used, then folding can be achieved, but it cannot provide in-situ support and gentle bending for complex three-dimensional configurations
Solution Approach 1:
The jig acts as an in-situ intermediary support structure that conforms to the interior volume of the package. The movable blocks provide gentle, distributed support during folding, preventing damage to the flexible substrate while achieving the desired three-dimensional configuration
Solution Approach 2:
The movable blocks on tracks provide dynamic, adjustable support during the folding process. The blocks can be positioned at different locations to accommodate various folding stages and can move to accommodate the changing geometry of the substrate as it is folded into its final three-dimensional shape
Data Source
Figure 1
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AI summary
A jig (55) includes a base (90) and one or more movable blocks (77A, 77B, 77C,77D). The base (90) has an upper surface (92), which is configured to receive a substrate (99) shaped as a flattened polyhedron having multiple facets (88A, 88B, 88C, 88D, 88F). The one or more movable blocks (77A, 77B, 77C, 77D) are configured to move on the base (90) so as to fold respective ones of the multiple facets (88A, 88B, 88C, 88D, 88E, 88F), and to hold the substrate (99) In a folded three-dimensional configuration.