Precision Wire Insertion System for PCB Aperture Alignment
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Solution Overview
Problem
Manual coupling of substrates such as printed circuit boards (PCBs) during manufacturing is prone to human error, leading to sloppy assembly and variability in wire insertion precision, which can affect circuit performance and consistency.
Innovation Solution
A precision wire insertion system that includes a wire supply with pre-stretching mechanisms, a slack-measuring device, a passive encoder, and a guidance nozzle with a cutting blade, which together ensure straight wire insertion and precise alignment of PCB apertures, minimizing slippage and curvature, and allowing for controlled cutting of wires between substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual coupling of substrates is used during manufacturing, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical operations with an automated wire insertion system that uses computer-controlled mechanisms to guide wires through apertures and perform precision cutting, eliminating human error while maintaining operational efficiency
Solution Approach 2:
The system incorporates self-aligning features where the wire path and aperture positions are automatically coordinated through programmed motion control, allowing the system to self-correct positioning without manual intervention
2Manufacturing precision
If automated wire insertion system is used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The automated system performs multiple functions including wire feeding, guidance, positioning, and cutting within a single integrated platform, reducing the need for separate manual operations and auxiliary devices
Solution Approach 2:
The patent introduces a computer control system as an intermediary that coordinates all mechanical components, simplifying the overall system architecture by centralizing control logic and enabling precise coordination without complex mechanical linkages
3Ease of operation
If hand-coupled PCB assembly is used, then ease of operation is improved, but reliability deteriorates
Solution Approach 1:
The system incorporates feedback mechanisms through computer-controlled monitoring of wire insertion depth, positioning accuracy, and cutting precision, enabling real-time adjustments to maintain consistent circuit performance across all assemblies
Solution Approach 2:
The system performs preliminary alignment and positioning of wires relative to aperture centers before actual insertion, ensuring that each wire is correctly positioned in advance to prevent misalignment and assembly errors
Data Source
AI summary
Systems, apparatuses and methods are described herein for precision insertion. In various embodiments, a feeder device may be configured to feed an object such as wire from a wire source into a wire path. In various embodiments, a guidance device with a channel that at least partially defines the wire path may receive the wire fed from the feeder device. In various embodiments, a base may be provided for mounting at least one of a first substrate having a first aperture and a second substrate having a second aperture so that the first aperture of the first substrate is aligned with the second aperture of the second substrate. In various embodiments, the base may be configured to be movable relative to the guidance device to position the first substrate or second substrate so that the first or second aperture is aligned with the wire path.