Press Station Assembly for Razor Blade Cartridges
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Solution Overview
Problem
Existing production line systems for attaching components to form assemblies, such as razor blade cartridges, face challenges in achieving high throughput and quality due to limitations in performing multiple operations simultaneously and ensuring consistent assembly features within tolerance.
Innovation Solution
A system that integrates multiple stations, including a press station with cleaning, inspection, and separation modules, along with a magazine changing system, to efficiently attach components to strips of material, utilizing a die module for cutting and shaping, and a welding module for fastening, while maintaining high production rates and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple operations are performed in a single press station, then productivity increases, but device complexity increases
Solution Approach 1:
The patent combines multiple operations (cutting, shaping, cleaning, inspection, and separation) into a single press station. The die module performs both cutting and shaping operations simultaneously on the band of material, while the cleaning module and inspection module are integrated into the same press station, allowing multiple functions to be executed in one location rather than requiring separate stations for each operation.
Solution Approach 2:
The press station is designed as a multi-functional unit that can perform diverse operations. The die module serves multiple purposes by both cutting individual strips from the band and shaping them simultaneously. The inspection module measures features of assemblies while they are still on the band, and the cleaning module removes contaminants, all within the same press station infrastructure, making the system versatile and reducing the need for multiple dedicated machines.
2Productivity
If high-speed operations are performed, then productivity increases, but manufacturing precision deteriorates
Solution Approach 1:
The inspection module measures one or more features of the assemblies while they are still attached to the band of material, before the assemblies are separated. This preliminary inspection allows quality verification to occur during the high-speed production process rather than as a separate post-processing step, ensuring that precision requirements are met while maintaining high throughput rates of 100 to 500 strokes per minute.
3Productivity
If continuous band of material is used, then productivity increases, but loss of substance increases
Solution Approach 1:
The die module cuts individual strips from the continuous band of material while leaving uncut portions that connect the strips. These uncut portions are extracted and removed as waste material in the scrap removal module. This approach allows the system to process continuous material for high productivity while systematically removing the necessary connecting portions that become waste, enabling separation of useful product from necessary waste material.
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 system enables rapid and precise attachment of components to strips, achieving high throughput and ensuring assemblies meet specified tolerances, with the ability to operate at rates of 100 to 500 strokes per minute and maintain quality by inspecting features like weld quality and alignment.
Implementation Method 1
a welding module that welds one component to each individual strip in the band of material
Implementation Method 2
the welding unit can include a laser that spot welds the components to the individual strips
Data Source
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AI summary
This invention relates to methods and systems for attaching components (51) to strips of material (25) to form assemblies (71), e.g., a system for fastening pre-sharpened razor blades to individual support strips (25) on a continuous band of material (24), such as a metal, to form discrete blade assemblies (71).