Multifunction End Effector for Thermoplastic Composite Assembly
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Solution Overview
Problem
Conventional methods for assembling thermoplastic composite articles require substantial manual labor, leading to limitations in accuracy and repeatability due to human involvement in cutting, picking up, placing, stacking, and welding processes.
Innovation Solution
A multifunction end effector apparatus comprising a robot with integrated cutting, vacuum, and welding heads, which automates the cutting, picking up, and welding of thermoplastic parts, reducing the need for manual intervention and improving process accuracy and repeatability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual labor is used for cutting, picking up, placing, stacking, and welding thermoplastic parts, then the process is simple to implement, but the accuracy and repeatability of the assembly process deteriorates
Solution Approach 1:
The patent combines multiple functions (cutting, picking up, placing, stacking, and welding) into a single integrated end effector system mounted on a robot. This merging of previously separate manual operations into one automated system resolves the contradiction by achieving high manufacturing precision through automation while accepting the necessary increase in device complexity as a trade-off for eliminating manual labor limitations.
Solution Approach 2:
The end effector is designed as a universal tool that performs multiple functions: the cutting head with ultrasonic cutter, the vacuum head for picking and placing, and the welding head with ultrasonic welder. This multi-functionality allows a single automated system to replace multiple manual operations, improving accuracy and repeatability across all assembly stages while consolidating device complexity into one versatile unit.
2Productivity
If manual labor is used for cutting and welding thermoplastic parts, then the equipment required is simple, but the productivity and efficiency of the assembly process deteriorates
Solution Approach 1:
The automated end effector system enables continuous operation by eliminating the need for manual intervention between cutting, picking, placing, and welding operations. The robot can continuously cycle through these operations without breaks or repositioning, maintaining continuous useful action and significantly improving productivity compared to manual methods that require human fatigue management and repositioning.
Solution Approach 2:
The patent replaces manual mechanical operations with automated ultrasonic technology. The ultrasonic cutter replaces manual knife cutting, and the ultrasonic welder replaces manual welding processes. This substitution of mechanical systems with automated ultrasonic mechanisms improves productivity by eliminating human speed limitations while the integrated design manages the resulting device complexity.
3Reliability
If automated system is implemented for cutting, picking up, and welding thermoplastic parts, then the accuracy and repeatability improves, but the device complexity increases
Solution Approach 1:
The end effector is segmented into distinct functional modules: a cutting head with ultrasonic cutter, a vacuum head with vacuum surface, and a welding head with ultrasonic welder. Each module is independently designed and mounted on the robot, allowing for specialized optimization of each function while maintaining overall system reliability. This segmentation enables consistent performance of each operation without requiring the entire system to be overly complex.
Solution Approach 2:
The robot acts as an intermediary that coordinates and positions the various heads of the end effector system. By using the robot's precise positioning and control capabilities, the system achieves high reliability and repeatability in all operations without requiring each component to be independently complex. The robot mediates between the different functional heads and the workpiece, ensuring consistent accuracy across cutting, picking, placing, and welding operations.
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 automated system enhances the accuracy and repeatability of the assembly process by eliminating the need for human involvement in critical stages, thereby improving the efficiency and consistency of thermoplastic composite article production.
Implementation Method 1
a cutting head including an ultrasonic cutter to cut a first thermoplastic part from a thermoplastic material
Implementation Method 2
a vacuum head including a vacuum surface to pick up the first thermoplastic part in response to a vacuum force applied at the vacuum surface
Implementation Method 3
a welding head including an ultrasonic welder to weld the first thermoplastic part to a second thermoplastic part
Data Source
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AI summary
Multifunction end effector apparatus (202) and methods for assembling thermoplastic composite articles. The apparatus includes a robot (204) and an end effector (202) coupled to the robot. The end effector includes a cutting head (250), a vacuum head (252) , and a welding head (254).