Pull Wire Assembly Removal and Sorting After Laser Welding
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Solution Overview
Problem
Manual assembly of pull wire assemblies is time-consuming, physically straining, and prone to defects, with operators needing to carefully handle small components under a microscope for precise laser welding.
Innovation Solution
An automated pull wire assembly machine that includes a transport device with a holding member and actuator to move assemblies between zones, a sorting tray assembly, and a rail with a cart for positioning and removing pull wire assemblies, utilizing a laser weld system for automated assembly and quality inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual assembly is used, then operator control and flexibility are maintained, but assembly time is excessive (50-75 seconds per assembly) and physical strain increases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated machine system that uses mechanical components (transport device, holding member, actuator, sorting tray assembly) to perform assembly tasks. This substitution eliminates the need for operators to manually handle small components under microscopes, thereby reducing assembly time from 50-75 seconds to a more efficient automated cycle while maintaining precision through controlled mechanical movements.
2Ease of operation
If manual assembly is used, then flexibility in handling is maintained, but manufacturing precision and reliability decrease due to fatigue and defects
Solution Approach 1:
The automated machine system performs assembly operations autonomously without requiring continuous human intervention. The transport device automatically positions components, the holding member secures assemblies, and the sorting tray assembly places finished products, creating a self-service system that eliminates operator fatigue and maintains consistent manufacturing precision across all assemblies.
Solution Approach 2:
The system incorporates quality inspection capabilities that provide feedback on assembly quality, allowing the machine to detect and correct issues before they become defects. This feedback mechanism ensures high manufacturing precision and reliability by continuously monitoring the assembly process and maintaining quality standards.
3Productivity
If automated assembly is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The automated assembly machine is divided into distinct functional modules: a transport device for moving components, a holding member for securing assemblies, an actuator for driving movements, and a sorting tray assembly for placing finished products. This segmentation allows each component to perform its specific function efficiently while keeping the overall system manageable and maintainable despite the increased automation.
4Ease of operation
If manual removal of assemblies is performed, then operator control is maintained, but risk of damage to components increases
Solution Approach 1:
The holding member acts as an intermediary between the assembly process and the final product removal. It securely holds the pull wire assembly during laser welding and transport, then releases it at the sorting tray assembly, eliminating the need for operators to manually handle and potentially damage the delicate components. This intermediary mechanism ensures component integrity throughout the automated process.
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
The machine automates the assembly process, reducing assembly time to under 20 seconds per single wire and under 40 seconds per dual wire, minimizing operator fatigue, and ensuring high-quality, defect-free production.
Implementation Method 1
The components need to be precisely positioned to achieve a reliable connection through a laser welding process
Data Source
AI summary
A removal system for a pull wire assembly machine includes a transport device having an actuator operably coupled to a holding member configured to hold and moved the assembled pull wire assembly from an assembly zone to a removal zone. The holding member releases the pull wire assembly into a sorting tray assembly configured to sort the pull wire assemblies, such as based on a quality assessment of the laser weld joint between the pull wire and the pull ring of the assembly. The sorting tray assembly deposits the pull wire assemblies into a storage tray assembly configured to store the sorted assemblies until gathered by an operator.