PCB Assembly Equipment for Razor Cartridge Manufacturing
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Solution Overview
Problem
Current manufacturing processes for razor cartridges are inflexible and costly, as they are dedicated to specific product families, requiring custom tooling and equipment, which limits the ability to switch between product families and increases capital costs.
Innovation Solution
Adopting standard printed circuit board (PCB) assembly modules, electronic assembly, and semiconductor assembly equipment to create a flexible assembly line that can handle multiple types of razor cartridge components using adaptable nozzles and modules, allowing for various operations such as picking, placing, and assembling components across different product families.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated assembly machines with custom tooling are used for each product family, then manufacturing precision and reliability are improved, but adaptability and versatility deteriorate
Solution Approach 1:
The patent applies universality by designing a single assembly machine capable of handling multiple product families through interchangeable end effectors and feed systems. The machine can be reconfigured to assemble different razor cartridge types (Sensor, Venus, Mach3, Fusion) without requiring dedicated equipment for each product line, thus achieving multi-functionality while maintaining precision through standardized interfaces and programmable control.
Solution Approach 2:
The patent implements dynamics through programmable control systems that allow the assembly machine to dynamically adapt its operations. The machine can switch between different assembly sequences, component types, and operational parameters based on the specific product being assembled, enabling flexible reconfiguration between product families while maintaining manufacturing precision through software-controlled adjustments.
2Manufacturing precision
If custom precision tooling equipment is designed for each product, then manufacturing precision is improved, but device complexity and capital cost increase
Solution Approach 1:
The patent reduces device complexity by replacing multiple custom tooling systems with a single universal assembly machine. The standardized end effectors and feed systems can be programmed to handle different component types, eliminating the need for separate precision tooling for each product family while maintaining assembly precision through controlled programming and standardized interfaces.
Solution Approach 2:
The patent applies parameter changes by using programmable control to adjust operational parameters (speed, position, force, sequence) rather than changing physical tooling parameters. This allows the same hardware to adapt to different product requirements by modifying software parameters, thereby reducing device complexity while maintaining manufacturing precision.
3Reliability
If dedicated assembly lines are used for each product family, then manufacturing reliability is improved, but productivity and flexibility deteriorate
Solution Approach 1:
The patent improves productivity by consolidating multiple dedicated assembly lines into a single universal machine that can produce different product families. This eliminates idle capacity when demand shifts between products, as the machine can be rapidly reconfigured through programming rather than requiring physical retooling, thereby maintaining reliability while increasing overall throughput.
Solution Approach 2:
The patent enhances flexibility through dynamic reconfiguration capabilities enabled by programmable control. The assembly machine can switch between product families and adjust operational parameters on-demand, allowing rapid response to changing demand patterns without sacrificing assembly reliability, thus improving overall productivity compared to static dedicated lines.
4Manufacturing precision
If custom feed systems are designed for each component type, then manufacturing precision is improved, but adaptability and ease of manufacture deteriorate
Solution Approach 1:
The patent applies universality to feed systems by designing standardized interfaces and interchangeable feed mechanisms that can handle different component types (caps, blades, cartridges) through a single system. The feed systems are programmed to accommodate various component geometries and feeding requirements, maintaining placement precision while enabling flexible handling of diverse components across different product families.
Data Source
AI summary
The invention discloses a novel application of standard printed circuit board (PCB) assembly modules, electronic assembly, and/or semiconductor assembly equipment for the assembly of consumer products, such as razor cartridges. In addition, nozzles of the pick/place component placement machine of the present invention may be desirably adapted to operate on type of razor cartridge component (e.g., blade, lubricating strip) disposed on a pallet. The adapted nozzle may include adaptors which may have an elongated portion, an angled portion, a tapered portion, a gripper portion, a curved portion, a rounded portion, a pointed tip, a stamper, a marker, a printer, a guide portion, a spring portion, a moveable leg, or any combination thereof, for operating on a razor cartridge component.