Needle Dispensing Drums for Precise Syringe Assembly
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Solution Overview
Problem
Manufacturing disposable needles and syringes with precise tolerances is challenging due to the need for individualizing and accurately locating components like the needle hub, cap, and syringe, especially in dental applications where different lengths and diameters are required, leading to inefficiencies in manufacturing and handling.
Innovation Solution
A needle dispenser system utilizing a singularizing drum and positioning drum with coordinated grooves and magnets, along with a needle sensor and controller, ensures precise alignment and transfer of needles to a gripper for consistent engagement with a hub, enabling efficient assembly of needles and syringes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If needles are manufactured with precise tolerances for individualization and accurate location relative to hubs and caps, then manufacturing precision is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The manufacturing system is divided into separate functional modules: a hopper for bulk needle storage, a singularizing drum for individual needle extraction, and a positioning drum for precise location. This segmentation allows each component to perform its specific function with optimized precision without requiring the entire system to be overly complex.
Solution Approach 2:
The positioning drum acts as an intermediary mechanism between the singularizing drum and the final assembly point. It receives needles from the singularizing drum and provides precise positioning relative to the hub and cap, thereby achieving high manufacturing precision without requiring direct complex positioning mechanisms.
2Manufacturing precision
If needles are individually located and precisely positioned, then manufacturing precision is improved, but productivity decreases due to the time-consuming nature of individual processing
Solution Approach 1:
Needles are stored in bulk in the hopper in a pre-arranged configuration, allowing multiple needles to be processed sequentially without repeated setup operations. The singularizing drum continuously extracts needles from the hopper, and the positioning drum continuously positions them, creating a streamlined flow that maintains precision while improving productivity.
Solution Approach 2:
The system maintains continuous operation through the coordinated rotation of the singularizing drum and positioning drum. Needles are continuously transferred from the hopper through the singularizing drum to the positioning drum and finally to the assembly point, eliminating idle time and maintaining consistent productivity while preserving positioning precision.
3Adaptability or versatility
If different needle lengths and diameters are manufactured for different dental applications, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The system is designed to dynamically accommodate different needle specifications through adjustable parameters in the singularizing and positioning drums. The drums can be configured to handle varying needle lengths and diameters, allowing the same manufacturing system to produce different needle types for mandibular and maxillary injections without requiring separate precision manufacturing lines for each specification.
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 system achieves accurate and efficient dispensing of needles, ensuring consistent alignment and transfer, thereby improving manufacturing efficiency and reducing errors in dental needle assembly.
Implementation Method 1
The positioning drum includes at least one magnet embedded within the positioning drum adjacent the at least one groove. The at least one magnet facilitates transfer of the needle from the singularizing drum to the positioning drum.
Data Source
AI summary
A needle dispenser includes a hopper configured to receive and hold a plurality of bulk needles for dispensing. A singularizing drum is positioned to rotate with a portion of the singularizing drum exposed to the interior of the hopper. The singularizing drum includes at least one groove in an outer surface of the singularizing drum. A positioning drum positioned to rotate adjacent to the singularizing drum. The positioning drum includes at least one groove in an outer surface of the positioning drum. The singularizing drum and the positioning drum rotate in coordination to pass a needle from the at least one groove of the singularizing drum to the at least one groove of the positioning drum.