Oscillating Fastener Needle Penetration Cycle
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Solution Overview
Problem
Automated plastic fastener dispensing devices experience needle deflection and damage when penetrating thick or dense materials, leading to permanent bending, breakage, or significant material damage.
Innovation Solution
A novel oscillating linear needle penetration cycle is implemented, involving partial penetration, partial withdrawal, and full penetration strokes to minimize lateral deflection and damage, using a reciprocating motion that adjusts stroke lengths based on material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a needle penetrates thick or dense materials in a single continuous motion, then penetration speed is improved, but needle deflection and damage occur
Solution Approach 1:
The penetration process is divided into multiple discrete strokes instead of a single continuous motion. The needle performs a first partial penetration stroke to reach a first depth, then a second penetration stroke to reach a second depth greater than the first, with intermediate withdrawal strokes between them. This segmentation allows the needle to penetrate thick or dense materials without excessive lateral deflection or damage while maintaining reasonable penetration speed.
2Loss of time
If a needle penetrates material with a single continuous stroke, then penetration time is reduced, but lateral deflection and material damage increase
Solution Approach 1:
The single continuous stroke is segmented into multiple penetration strokes with intermediate withdrawals. The needle penetrates to a first depth, withdraws partially, then penetrates to a greater second depth. This multi-stage approach reduces lateral deflection and material damage compared to a single continuous stroke, while the withdrawals are minimized to reduce total penetration time.
3Productivity
If the needle penetrates to full depth in one stroke, then operational efficiency is improved, but needle bending and breakage risk increase
Solution Approach 1:
The full-depth penetration is achieved through segmented strokes: a first stroke to a first depth, intermediate withdrawal, then a second stroke to a second depth greater than the first. This segmentation reduces the risk of needle bending or breakage by avoiding excessive lateral deflection that would occur in a single full-depth stroke, while maintaining operational efficiency through minimized intermediate withdrawals.
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
A method for penetrating a material (81) with a fastener dispensing needle (59) includes the steps of partially penetrating the material using a first penetration stroke, partially withdrawing the needle from the material using a first withdrawal stroke and, in turn, fully penetrating the material using a second penetration stroke. Once fully penetrated, a plastic fastener (18) is dispensed from the fastener dispensing needle. Thereafter, the fastener dispensing needle is fully withdrawn from the material. Additional partial penetration and withdrawal strokes could be incorporated into the needle penetration cycle in a repeating pattern, as needed, with each penetration stroke. The use of an oscillating, back-and-forth, linear needle penetration cycle serves to minimize the risk of lateral needle deflection which can result in bending or breakage of the needle as well as damage to the penetrated material.