Position Sensor Assembly Jig for Folding 3D Substrates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of triple-axis position sensors (TAPS) with foldable substrates, such as flexible printed circuit boards, is complex and time-consuming, requiring manual or robotic operation to fold and fasten facets onto a solid polyhedron, which complicates the manufacturing process and increases production costs.
Innovation Solution
A jig system comprising a base with tracks and movable blocks that fold and fasten facets of a substrate onto a solid polyhedron, allowing for efficient manual or robotic assembly, with a fixation apparatus to secure the blocks and a knob for fastening the final facet, enabling hands-free coupling of adjacent edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual or robotic operation is used to fold and fasten facets onto a solid polyhedron, then the assembly can be completed, but the manufacturing process becomes complex and production costs increase
Solution Approach 1:
A jig system is introduced as an intermediary device between the operator and the substrate assembly process. The jig includes a base with tracks and movable blocks that guide the folding and fastening operations, eliminating the need for complex manual or robotic manipulation while simplifying the manufacturing process
Solution Approach 2:
The assembly process is divided into discrete, manageable steps using separate functional components: movable blocks for folding individual facets, fixation apparatus for securing blocks at predefined positions, and a knob for final fastening. This segmentation allows each component to perform a specific function independently, reducing overall system complexity
2Manufacturing precision
If multiple movable blocks are used to fold and fasten facets, then assembly precision is improved, but the number of components and device complexity increase
Solution Approach 1:
The movable blocks serve multiple functions: they guide the folding of facets, hold the substrate in the folded three-dimensional configuration, and fasten the facets to the solid polyhedron. This multi-functionality reduces the need for separate components for each operation, thereby reducing overall device complexity while maintaining precision
Solution Approach 2:
The movable blocks can be repositioned along tracks on the base and fixated at predefined positions using the fixation apparatus. This dynamic capability allows the same set of blocks to accommodate different folding sequences and configurations, providing precision for multiple assembly scenarios without requiring dedicated components for each case
3Stability of the object's composition
If a fixation apparatus is used to secure movable blocks at predefined positions, then assembly stability is improved, but the time required for assembly operations increases
Solution Approach 1:
The fixation apparatus is designed to quickly secure the movable blocks at predefined positions on the base. By preparing the fixation mechanism in advance and enabling rapid engagement, the system achieves stable configuration fixation without significantly increasing assembly time
Solution Approach 2:
The movable blocks are designed to work in conjunction with the fixation apparatus in a self-securing manner. Once the blocks are positioned at the correct locations, the fixation apparatus automatically secures them, reducing the need for additional manual intervention and minimizing the time added to the assembly process
Data Source
AI summary
A jig includes a base and one or more movable blocks. The base has an upper surface, which is configured to receive a substrate shaped as a flattened polyhedron having multiple facets. The one or more movable blocks are configured to move on the base so as to fold respective ones of the multiple facets, and to hold the substrate in a folded three-dimensional configuration.