Hypodermic Needle Bending Apparatus with Servo Control
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Solution Overview
Problem
Existing methods for bending hypodermic needles are imprecise, inefficient, and prone to damage, especially when forming multiple bends at different angles or directions, and are not suitable for mass production.
Innovation Solution
A programmable apparatus with a bending die, servo-actuated slide, and pneumatic-actuated bending pin, combined with machine vision and a programmable controller, allows for precise and efficient formation of one or more bends in hypodermic needles, enabling user-selectable angles and directions with minimal tooling changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual bending technique is used, then flexibility in forming bends is improved, but manufacturing precision and reliability deteriorate
Solution Approach 1:
The apparatus employs a programmable controller that enables dynamic adjustment of bending parameters including angle, direction, and position. The system can adapt to different bending requirements through software programming rather than physical reconfiguration, allowing high versatility while maintaining consistent precision through automated control
Solution Approach 2:
The system changes bending parameters (angle, direction, position) through programmable control rather than manual adjustment. This allows the same apparatus to form various bends by simply changing control parameters, achieving both adaptability and precision simultaneously
2Device complexity
If manual bending technique is used, then device complexity is reduced, but productivity and manufacturing precision deteriorate
Solution Approach 1:
The apparatus is designed as a multi-functional system that can form multiple bends at different angles and positions using a single integrated device. The programmable controller enables the same hardware to perform various bending operations, achieving high productivity without proportionally increasing device complexity
Solution Approach 2:
The system uses automated servo-actuated mechanisms that self-regulate bending forces and positions based on programmed parameters. The apparatus performs bending operations autonomously without continuous manual intervention, significantly increasing productivity while maintaining a relatively simple mechanical structure
3Ease of manufacture
If excessive force is applied during manual bending, then bending is achieved, but needle damage increases
Solution Approach 1:
The apparatus incorporates sensors and programmable control that monitor bending forces and needle position in real-time. The system adjusts applied force based on feedback signals, ensuring sufficient force is applied to achieve bending while preventing excessive force that could damage the needle or lumen
Solution Approach 2:
The bending force is dynamically adjusted during the bending process based on programmed parameters and sensor feedback. The servo-actuated mechanisms can modulate force application to match the needle's mechanical properties, achieving bending without causing damage
4Adaptability or versatility
If multiple bends are formed using manual technique, then versatility is improved, but manufacturing precision and time efficiency deteriorate
Solution Approach 1:
The apparatus can form multiple bends in continuous sequence without requiring manual repositioning or tool changes between bends. The programmable controller coordinates the servo mechanisms to perform multiple bending operations in a continuous automated cycle, significantly reducing time loss while maintaining precision for each bend
Solution Approach 2:
The system pre-programs the sequence of multiple bends before production begins. All bending parameters for multiple bends are predetermined and stored in the controller, allowing the apparatus to execute the complete bending sequence efficiently without time-consuming adjustments between bends
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 apparatus enables precise, efficient, and repeatable bending of hypodermic needles in various directions and angles, suitable for mass production, reducing the risk of damage and improving comfort in medical applications.
Implementation Method 1
The bending pin is rotatable about a bending axis passing through the linear path, and is configured to press a portion of the hypodermic needle against the bending die as the bending pin rotates to form a bend in the hypodermic needle
Data Source
AI summary
An apparatus for bending a hypodermic needle includes a bending die, a needle gripper configured to grasp the hypodermic needle, a servo-actuated slide operatively coupled to the needle gripper, and a servo- or pneumatically-actuated bending pin. The servo-actuated slide is configured to translate the needle gripper along a linear path adjacent to the bending die for positioning the hypodermic needle at a predetermined bending position with respect to the bending die. The bending pin is rotatable about a bending axis passing through the linear path. The bending pin is configured to press a portion of the hypodermic needle against the bending die as the bending pin rotates to form a bend in the hypodermic needle.