LED Lamp Cap Assembly with Lead Wire Threading and Positioning
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Solution Overview
Problem
The manual assembly of LED lamp caps is inefficient and prone to errors, leading to poor quality and damage to the LED lamp wick during the installation process, particularly due to the separation of the LED lamp bead from its lead wire.
Innovation Solution
A device comprising multiple feeding devices and mechanisms for automatically assembling the LED lamp cap, including a first feeding device for the heat sink base, a second for the LED lamp bead, a third for the lamp tube, and a positioning-mounting mechanism with a lead wire threading device to securely attach the lead wire to the heat sink base, ensuring accurate and stable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used for LED lamp cap, then flexibility and simplicity are maintained, but production efficiency is poor and quality is low
Solution Approach 1:
The assembly system is divided into multiple independent feeding devices (first feeding device for heat sink base, second feeding device for LED lamp bead, third feeding device for lamp tube) and a positioning-mounting mechanism. Each component has its own dedicated feeding and positioning system, allowing parallel operation and improving overall productivity while maintaining modular simplicity.
Solution Approach 2:
The automatic assembly device performs self-service by automatically feeding, positioning, and assembling components without manual intervention. The system includes automatic lead wire threading and securing functions that self-correct potential issues during assembly, eliminating the need for external manual operations.
2Reliability
If manual assembly is used, then operation simplicity is maintained, but assembly quality and reliability are poor
Solution Approach 1:
Each component (heat sink base, LED lamp bead, lamp tube) has its own dedicated feeding device that pre-positions and pre-orients components before assembly. The positioning-mounting mechanism performs preliminary alignment and securing actions, ensuring high assembly quality and reliability before final assembly occurs.
Solution Approach 2:
The system replaces manual mechanical assembly operations with automated positioning and mounting mechanisms. The lead wire threading device automatically guides and secures lead wires through mounting holes, eliminating manual manipulation that causes variability and reducing assembly quality issues.
3Productivity
If lead wire is drawn by external force during assembly, then assembly progress is made, but LED lamp bead separates from lead wire causing scrap
Solution Approach 1:
The positioning-mounting mechanism performs preliminary securing actions on the lead wire before final assembly. The lead wire threading device预先 guides the lead wire through the mounting hole and secures it in place, preventing separation even when external forces are applied during subsequent assembly operations.
Solution Approach 2:
The positioning-mounting mechanism provides beforehand cushioning by pre-securing the lead wire and LED lamp bead connection. This preliminary securing action creates a buffer that protects against potential separation caused by external forces during the assembly process, preventing scrap and maintaining reliability.
Data Source
AI summary
A device for automatically installing a lamp tube of an intelligent LED lamp cap, including a first feeding device for feeding a heat sink base and a second feeding device for feeding a LED lamp bead out to an outlet of the first feeding device and assembling the LED lamp bead with the heat sink base. A third feeding device is arranged on a side of the first feeding device for feeding a lamp tube. A positioning-mounting mechanism is arranged on a side of the third feeding device and is configured to assemble the heat sink base with a lamp tube. A lead wire threading device is arranged on a side of the positioning-mounting mechanism and is configured to guide a lead wire of the LED lamp bead to pass through a mounting hole on the heat sink base.