Pull Wire Assembly Removal and Sorting for Weld Quality Control
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Solution Overview
Problem
The manual assembly of pull wire assemblies is time-consuming, physically straining for operators, and prone to defects due to the small size and complexity of the components, requiring precise handling and laser welding.
Innovation Solution
An automated pull wire assembly machine that includes a transport device with a holding member and actuator to move the assembly between zones, a sorting tray assembly, and a control system with vision and sorting capabilities to automate the assembly, welding, and removal process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly is used with miniature pliers and microscope observation, then precise positioning of small components is 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 system that uses precision positioning mechanisms and robotic manipulation. The automated assembly machine substitutes human hands and tools with programmable mechanical systems capable of sub-millimeter positioning accuracy while operating continuously without fatigue, thereby achieving both precision and high speed assembly.
Solution Approach 2:
The automated assembly system performs positioning and assembly operations autonomously without human intervention. The machine self-regulates the positioning of pull wires and pull rings, self-adjusts tool positions, and self-completes the welding process, eliminating the need for operators to manually handle delicate components while maintaining precision and increasing throughput.
2Device complexity
If manual handling of small components is used, then assembly can be performed with simple equipment, but the risk of producing defective parts increases due to operator fatigue and physical strain
Solution Approach 1:
The patent replaces manual mechanical operations with automated mechanical systems that eliminate human fatigue and variability. The automated positioning and assembly mechanisms maintain consistent force application and positioning accuracy throughout operation, preventing defects caused by operator tiredness while using equipment that appears simple in overall architecture.
Solution Approach 2:
The automated assembly system incorporates sensors and control systems that provide real-time feedback on component positioning, force application, and assembly quality. This feedback loop enables the machine to detect and correct positioning errors or excessive forces before defects occur, significantly reducing the defect rate compared to manual operations.
3Productivity
If automated assembly machinery is introduced to increase productivity, then assembly speed improves, but the complexity of the device increases
Solution Approach 1:
The automated assembly machine is designed as a multi-functional system that performs multiple operations (positioning, gripping, welding, quality inspection) within a single integrated platform. This universal design consolidates what could be multiple separate complex devices into one cohesive system, achieving high productivity while managing overall device complexity through functional integration.
Solution Approach 2:
The patent merges the positioning system, manipulation system, welding system, and quality control system into a single integrated automated assembly machine. By combining these functions into one coordinated system rather than separate devices, the patent achieves high assembly speed while avoiding the cumulative complexity that would result from multiple independent machines working in sequence.
4Device complexity
If manual removal of assembled components from fixturing is performed, then simple equipment can be used, but the risk of damaging wires near the joint increases
Solution Approach 1:
The patent replaces manual removal operations with automated manipulation systems that use programmable gripping and positioning mechanisms. These automated systems apply controlled forces and follow precise motion paths during component removal, eliminating the risk of accidental wire damage that occurs during manual handling while keeping the removal equipment relatively simple in design.
Data Source
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AI summary
A removal system (500) for a pull wire assembly machine (100) includes a transport device (502) having an actuator (538) operably coupled to a holding member (518) configured to hold and moved the assembled pull wire assembly (10) from an assembly zone (102) to a removal zone (104). The holding member releases the pull wire assembly into a sorting tray assembly (504) 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 (30) 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.