Pull Wire Placement for Precise Slot Alignment in Laser Welding
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Solution Overview
Problem
The 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
An automated pull wire assembly machine with a wire placement system, ring placement system, laser weld system, and removal system, utilizing grippers, actuators, and vision systems to automate the assembly process, ensuring precise positioning and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used, then flexibility and simplicity are maintained, but assembly time is excessive and productivity is low
Solution Approach 1:
The automated assembly system is divided into distinct functional modules: a wire placement system with wire guide device and wire gripper assembly, a ring placement system with ring manipulator, and a laser weld system. Each module operates independently but coordinates through a control system, allowing the complex automation task to be managed through modular components rather than a monolithic system.
Solution Approach 2:
A control system acts as an intermediary between the various automated components (wire placement system, ring placement system, laser weld system) and the operator. This control system coordinates the timing and sequencing of operations, enabling high-speed automated assembly while maintaining system simplicity through centralized management.
2Manufacturing precision
If manual assembly is used, then device complexity is low, but manufacturing precision and positioning accuracy deteriorate
Solution Approach 1:
The system replaces manual mechanical positioning with automated mechanical systems. The wire placement system uses a wire guide device and wire gripper assembly with actuators to precisely position wires, while the ring manipulator automatically positions pull rings. These automated mechanical systems provide consistent sub-millimeter positioning accuracy that cannot be achieved through manual operation alone.
Solution Approach 2:
The positioning precision is achieved by controlling key parameters of the automated systems: the wire placement system controls wire feed rate and positioning speed, the ring manipulator controls ring placement speed and position, and the laser weld system controls welding parameters. These parameter controls enable precise positioning without requiring overly complex mechanical structures.
3Duration of action of moving object
If manual assembly is used, then equipment simplicity is maintained, but assembly time and cycle duration increase
Solution Approach 1:
The automated system enables continuous operation through coordinated action of multiple systems. The wire placement system continuously feeds and positions wires, the ring manipulator continuously places rings, and the laser weld system continuously performs welding operations. This continuous coordinated action reduces assembly cycle time from manual seconds to automated fractions of seconds, achieving high-speed production.
Solution Approach 2:
The system performs preliminary positioning actions before the actual welding operation. The wire placement system pre-positions wires in correct locations, and the ring manipulator pre-positions rings before the laser weld system activates. This preliminary automated positioning eliminates time-consuming manual alignment steps and enables rapid continuous production.
4Reliability
If manual assembly is used, then system simplicity is maintained, but reliability and quality consistency deteriorate
Solution Approach 1:
The control system incorporates feedback mechanisms to monitor and maintain assembly quality. Sensors detect wire position, ring position, and welding parameters in real-time, providing feedback to the control system. This feedback enables automatic adjustments to maintain consistent positioning accuracy and welding quality, ensuring reliable production without requiring complex manual inspection procedures.
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 automated assembly process significantly reduces assembly time, minimizes defects, and reduces operator strain, enabling high-quality production with efficient throughput.
Implementation Method 1
laser weld system configured to laser weld the pull wire to the pull ring in the slot
Data Source
AI summary
A wire placement system for a pull wire assembly machine configured to assemble a pull wire to a pull ring is provided. The wire placement system includes a wire guide device configured to guide the pull wire at an assembly zone of the pull wire assembly machine. The wire placement system includes a wire gripper assembly including a wire gripper configured to grip the pull wire and a wire gripper actuator operably coupled to the wire gripper. The wire gripper actuator is configured to move the pull wire into a slot in the pull ring to place the pull wire in the assembly zone for laser welding the pull wire to the pull ring in the slot.