Automated Lead Insertion System with Flame Heating
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Solution Overview
Problem
Manual lead insertion into glass tubes for temperature sensors is inefficient and lacks precise control over heating, affecting the quality of the sensors.
Innovation Solution
A lead insertion system comprising two robots with grippers and a flame heater, allowing for automated and controlled heating of both the glass tube and lead to facilitate smooth insertion, ensuring the glass tube is heated to a predetermined softening degree.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual lead insertion is used, then operational flexibility is maintained, but productivity is low and heating precision is poor
Solution Approach 1:
The system enables automated lead insertion through robots that autonomously perform gripping, heating, and insertion operations without continuous human intervention, thereby improving productivity while managing complexity through automation
Solution Approach 2:
Manual mechanical operations are replaced with automated robotic systems equipped with specialized grippers and integrated heating capabilities, transitioning from human-operated mechanical processes to automated electromechanical systems
2Manufacturing precision
If manual heating control is used, then operational simplicity is maintained, but heating precision and temperature control are insufficient
Solution Approach 1:
The system incorporates temperature sensors and control systems that monitor and adjust heating parameters in real-time, ensuring precise temperature control of the glass tube during the lead insertion process
Solution Approach 2:
The robotic system integrates multiple functions including gripping, heating, and insertion control into a single automated platform, achieving precise heating control while managing overall system complexity through functional integration
3Manufacturing precision
If heating time is not accurately controlled, then process simplicity is maintained, but glass tube softening degree cannot be precisely achieved
Solution Approach 1:
The system uses temperature sensors and control algorithms to monitor heating duration and temperature simultaneously, adjusting the heating process in real-time to achieve the precise softening degree required for successful lead insertion
Solution Approach 2:
The system pre-calculates and controls the heating duration based on the required softening degree, ensuring the glass tube reaches the optimal state for insertion before the lead is introduced
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 system enables efficient and precise automatic insertion of leads into glass tubes, improving the quality and consistency of temperature sensors by maintaining the glass tube in a softened state during the process.
Implementation Method 1
a flame heater heating the glass tube gripped by the first robot and the lead gripped by the second robot with a flame
Data Source
AI summary
A lead insertion system adapted to insert a lead into a glass tube includes a first robot on which a first gripper is mounted and a second robot on which a second gripper is mounted. The first gripper grips the glass tube and the second gripper grips the lead. The lead insertion system includes a flame heater heating the glass tube gripped by the first robot and the lead gripped by the second robot with a flame. The second robot inserts the lead into the glass tube held by the first robot with the lead heated by the flame and the glass tube heated and softened by the flame.