Magnetic Shaft Ring Detection Circuit for Assembly Verification
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Solution Overview
Problem
In the assembly of machine parts, particularly in automotive manufacturing, visual inspection for the presence of a metal ring on shafts is prone to human error due to fatigue and distraction, leading to potential defects that can cause hazardous conditions for both assembly line workers and end-users.
Innovation Solution
An apparatus with a cylindrical inner cavity, electrical contact, and side magnets that detect the presence of a metal ring on a conductive shaft by completing an electrical circuit when the ring is properly attached, providing signals for correct or incorrect attachment through light, audio, or vibration feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If operators perform detailed visual inspection of each component to prevent assembly errors, then product quality improves, but assembly speed decreases due to the time required for careful inspection
Solution Approach 1:
The automated detection system replaces the slow manual visual inspection process with rapid automated sensing that can detect ring presence and proper assembly in fractions of a second, maintaining high manufacturing precision while dramatically increasing assembly line speed
Solution Approach 2:
The system performs detection during or immediately after the assembly process itself, rather than requiring a separate post-assembly inspection step, allowing quality verification to occur in-line without slowing down the overall production rate
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 solution significantly reduces human error in the assembly process by providing immediate feedback on the correct attachment of the metal ring, ensuring the quality and safety of assembled components.
Implementation Method 1
one or more side magnets disposed in a magnet recess in the inner side surface of the body such that the one or more side magnets are recessed from the inner side surface, the magnet recess parallel to the inner end surface and positioned such that a shaft recess of the conductive shaft aligns with the magnet recess in the inner side surface when the conductive shaft is inserted into the inner cavity
Implementation Method 2
one or more side magnets disposed in a magnet recess in the inner side surface of the body
Data Source
AI summary
An apparatus and method for determining whether a conductive ring is attached to an electrically conductive shaft. The body of the apparatus includes an electrical contact and side magnets positioned in a recess along the circumference of the cavity. When the shaft is received by the body, the electrical contact is in contact with the conductive shaft and the side magnets in the recess are in contact with the ring attached to the shaft, if present. An electrical signal is provided to the shaft and ring via the magnets and an output signal is generated. The output signal is indicative of whether the ring is attached to the shaft.