Vacuum Nozzle Ring Manipulator for Pull Wire Laser Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual assembly of pull wire assemblies is time-consuming, prone to defects, and physically straining for operators, with components requiring precise positioning for reliable laser welding.
Innovation Solution
A robotic pull wire assembly machine with a ring manipulator and end effector using vacuum nozzles to hold pull rings, a wire placement system, laser weld system, and removal system to automate the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly is used with miniature pliers and microscope, then precise positioning can be achieved, but assembly time is excessive (50-75 seconds per assembly) and operator fatigue increases
Solution Approach 1:
The patent replaces manual mechanical assembly with an automated robotic system that uses a vacuum nozzle to grasp the pull ring and a laser welder to join components. This substitution eliminates the need for manual manipulation with miniature pliers while maintaining positioning precision through automated control, thereby dramatically increasing assembly speed and eliminating operator fatigue.
Solution Approach 2:
The automated system performs the assembly task autonomously without human intervention. The robotic arm with vacuum nozzle automatically grasps and positions the pull ring, and the laser welder automatically joins the pull wire to the pull ring, making the system self-sufficient for the complete assembly process.
2Ease of operation
If manual assembly is used, then flexibility in handling components is maintained, but physical strain on operator increases and defect risk increases
Solution Approach 1:
The patent replaces manual handling with an automated robotic system that uses a vacuum nozzle to grasp the pull ring. This eliminates physical strain on operators while maintaining consistent, controlled handling that reduces the risk of defects. The laser welding process also eliminates manual manipulation during welding, further reducing defect risk.
3Productivity
If automated robotic system is introduced, then assembly time is reduced and productivity increases, but device complexity increases
Solution Approach 1:
The robotic arm is designed to perform multiple functions: it holds the vacuum nozzle for grasping the pull ring, positions components precisely, and coordinates with the laser welder for joining operations. This multi-functionality reduces the need for separate specialized devices, thereby managing system complexity while achieving high productivity.
4Manufacturing precision
If vacuum nozzle is used to hold pull ring, then precise positioning is achieved, but the system requires additional components increasing complexity
Solution Approach 1:
The vacuum nozzle acts as an intermediary between the robotic arm and the pull ring. It provides a simple yet effective mechanism for grasping and positioning the pull ring with high precision without requiring complex mechanical grippers or clamping mechanisms, thereby managing end effector complexity while achieving accurate positioning.
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
Automates the assembly process, reducing assembly time, improving precision, and minimizing operator fatigue while ensuring high-quality laser welds.
Implementation Method 1
The vacuum ports create a vacuum in the vacuum chamber to hold the pull ring in the vacuum chamber
Data Source
AI summary
A ring manipulator for a pull wire assembly machine configured to assemble a pull wire to a pull ring is provided. The ring manipulator includes a robotic arm that includes a mounting base and link arms attached to the mounting base and to each other at joints. The robotic arm is movable in three-dimensional space. The robotic arm has a distal end. The ring manipulator includes an end effector at the distal end of the robotic arm. The end effector includes a vacuum nozzle includes a vacuum chamber and vacuum ports in the vacuum chamber. The vacuum chamber configured to receive the pull ring. The vacuum ports create a vacuum in the vacuum chamber to hold the pull ring in the vacuum chamber.