Pull Wire Placement for Precise Slot Alignment and Laser Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual assembly of pull wire assemblies is time-consuming, prone to defects, and physically demanding, leading to operator fatigue and increased defect rates due to the small size and precise positioning requirements of pull wires and pull rings.
Innovation Solution
An automated pull wire assembly machine with a wire placement system, ring placement system, laser weld system, and removal system, utilizing a control system and vision system to automate the assembly process, ensuring precise alignment and welding of pull wires to pull rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly is used with miniature pliers and microscope observation, then precise positioning of pull wires in slots 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 operations with an automated robotic system featuring a programmable end effector that performs wire feeding, gripping, and placement operations. This automation eliminates the need for operators to manually manipulate tiny components with miniature pliers while maintaining precise positioning through controlled mechanical movements and vision guidance.
Solution Approach 2:
The system incorporates self-positioning mechanisms where the automated end effector automatically adjusts wire feed length, gripping force, and placement position based on real-time feedback from vision systems and sensors. The machine performs self-calibration and adaptive positioning without requiring manual intervention, enabling both high speed and precision.
2Ease of manufacture
If manual handling of tiny components is performed, then assembly can be completed, but physical strain on operator increases leading to fatigue and higher defect rates
Solution Approach 1:
The patent replaces manual mechanical operations with automated robotic manipulation. The programmable end effector consistently performs wire feeding, gripping, and placement with uniform precision, eliminating human factors such as fatigue, tremor, and inconsistent force application that lead to defects in manual assembly of tiny components.
Solution Approach 2:
The system incorporates vision systems and sensors that provide real-time feedback on wire position, placement accuracy, and assembly quality. This feedback loop enables automatic correction of positioning errors and immediate detection of potential defects, ensuring high reliability without operator intervention.
3Reliability
If precise positioning is required for laser welding, then connection reliability improves, but assembly time increases due to careful manual positioning
Solution Approach 1:
The automated end effector performs preliminary positioning of the wire before laser welding, pre-aligning components with precise control. The system pre-feeds the wire to the exact required length and position, and pre-grips it with controlled force, eliminating the need for time-consuming manual positioning adjustments while ensuring alignment accuracy for reliable laser welding.
Solution Approach 2:
The patent replaces manual positioning operations with automated robotic positioning that maintains precise control throughout the assembly process. The programmable end effector consistently achieves the required positioning accuracy for laser welding through controlled mechanical movements, eliminating the time penalty associated with careful manual positioning.
4Productivity
If automated machine assembly is implemented, then assembly speed and productivity improve, but system complexity increases
Solution Approach 1:
The patent employs a multi-functional programmable end effector that can perform multiple operations (wire feeding, gripping, placement, and positioning) with a single device. This universal toolhead reduces the need for multiple specialized components and simplifies the overall system architecture while maintaining high automation capability and productivity.
Solution Approach 2:
The system merges multiple functions into integrated modules: the end effector combines wire feeding, gripping, and placement mechanisms; the vision system integrates guidance and quality inspection; and the control system coordinates all operations. This functional integration reduces system complexity compared to having separate systems for each operation.
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 improved throughput and efficient sorting of completed assemblies.
Implementation Method 1
laser weld system configured to laser weld the pull wire to the pull ring
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A wire placement system (200) for a pull wire assembly machine (100) configured to assemble a pull wire (20) to a pull ring (30) is provided. The wire placement system includes a wire guide device (262) configured to guide the pull wire at an assembly zone (102) of the pull wire assembly machine. The wire placement system includes a wire gripper assembly (264) including a wire gripper (280) configured to grip the pull wire and a wire gripper actuator (284) operably coupled to the wire gripper. The wire gripper actuator is configured to move the pull wire into a slot (40) 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.