Magnetic Switch Sensor Line With Digital Sorting and Ordered Assembly
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Solution Overview
Problem
The production process of magnetic switch sensors lacks automation, leading to high labor costs and inefficient processing due to independent, manual handling of magnetic sensitive elements and components.
Innovation Solution
A whole-process digital processing system comprising a master control module and modules for sorting, pin processing, lead processing, welding, casing, and glue injecting, integrated with a database and testing modules for automated, ordered production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual handling and independent processing modules are used for magnetic sensitive elements and components, then the system is simpler to implement, but production automation is low and labor cost is high
Solution Approach 1:
The patent merges multiple independent processing modules (magnetic sensitive element sorting, pin processing, lead processing, welding, casing, and glue injecting) into an integrated automated production line controlled by a central control system. This combining of previously separate manual operations into a unified automated system directly resolves the contradiction by achieving high production automation while managing system complexity through modular integration.
Solution Approach 2:
The central control system serves multiple functions: it controls all processing modules, manages material inventory through the database module, coordinates the workflow according to order information, and monitors production status. This multi-functional control architecture enables high automation without requiring separate control systems for each module, thus resolving the contradiction between automation extent and system complexity.
2Productivity
If manual transfer and independent processing are used, then the processing steps are simpler to manage, but productivity is low and labor cost is high
Solution Approach 1:
The automated production line enables continuous processing where magnetic sensitive elements flow sequentially through sorting, pin processing, lead processing, welding, casing, and glue injecting without manual intervention between steps. This continuous automated workflow significantly increases productivity compared to discrete manual operations, while the modular design keeps system complexity manageable.
Solution Approach 2:
The database module tracks inventory information of magnetic sensitive elements, pins, leads, and other materials, providing feedback to the control system. This feedback mechanism enables automatic material management and production scheduling, increasing productivity by ensuring the right materials are available at the right time, while avoiding the complexity of manual inventory tracking.
3Loss of substance
If materials are prepared in advance without order-based control, then the production process is simpler to initiate, but material waste increases and inventory management becomes complex
Solution Approach 1:
The system performs preliminary actions by pre-processing magnetic sensitive elements (sorting and grading) and preparing material inventory information in advance, but only to the extent needed for confirmed orders. The database module tracks what materials are available and what orders are pending, enabling the system to prepare materials just-in-time rather than in excessive quantities, thus reducing waste while managing inventory complexity through digital tracking.
Solution Approach 2:
The control system automatically manages material inventory and production scheduling based on order information and database records. It self-regulates the flow of materials through the production line, ordering and allocating materials as needed without manual intervention. This self-service capability reduces material waste by preventing over-preparation while keeping inventory management simple through automated digital tracking rather than complex manual systems.
Data Source
AI summary
A processing system includes a master control module, an order module, a magnetic sensitive element sorting module, a pin processing module, a lead processing module, a pin lead welding module, a casing module and a glue injecting module, wherein the magnetic sensitive element sorting module is configured to grade and screen magnetic sensitive elements, the pin processing module is configured to process pins of magnetic sensitive elements, the lead processing module is configured to process wires into leads, the pin lead welding module is configured to weld leads on the pins of magnetic sensitive elements to form sensing elements, the casing module is configured to sleeve the sensing elements into the accommodating cavity of a shell, and the glue injecting module is configured to inject glue into the accommodating cavity of the shell to encapsulate the sensing elements and form magnetic switch sensors.