Robotic Cable Assembly Joining for Precise PCB Wire Connections
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Solution Overview
Problem
The manual process of connecting thin wires to electrodes on catheters and printed circuit boards (PCBs) is labor-intensive, requires skilled personnel, and increases manufacturing costs due to the delicate and precise nature of the task.
Innovation Solution
An automated robotic system that concurrently builds cable assemblies from wires and connects their ends to substrates, such as PCBs, using grippers and a joining tool to maintain wire tension and precision during welding or soldering processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual process is used to connect thin wires to electrodes and PCBs, then precision and accuracy can be achieved, but labor costs increase and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that uses computer-controlled grippers to manipulate wires and positioning tools. The robotic system performs wire stripping, positioning, and connection operations automatically, eliminating manual labor while maintaining precision through programmable control and feedback mechanisms.
Solution Approach 2:
The robotic system is designed to perform all connection operations autonomously without human intervention. The system self-regulates wire tension, positioning, and connection parameters through integrated sensors and control algorithms, enabling continuous operation and significantly improving productivity while maintaining consistent precision.
2Ease of operation
If manual wire stripping and connection process is used, then delicate handling is possible, but skilled personnel are required and costs increase
Solution Approach 1:
The patent replaces skilled manual operations with automated robotic manipulators equipped with specialized grippers and tools. The system uses computer vision and force feedback to delicately handle thin wires, performing stripping and connection operations with precision that exceeds human capability while requiring no specialized skills from operators.
Solution Approach 2:
The robotic system acts as an intermediary between the operator and the delicate wire manipulation tasks. The system translates high-level commands into precise robotic movements, isolating the operator from the complexity of delicate handling while maintaining the ability to perform fine manipulations through programmable control and sensor feedback.
3Productivity
If automated robotic system is used to build cable assemblies, then productivity increases and labor costs decrease, but device complexity increases
Solution Approach 1:
The robotic system is designed as a multi-functional platform that can perform wire stripping, positioning, tensioning, and connection operations using the same robotic manipulator and tooling system. This universal approach consolidates multiple functions into a single integrated system, improving productivity while managing complexity through standardization and modularity.
Solution Approach 2:
The patent combines wire preparation, positioning, and connection operations into a single integrated robotic workflow. The system merges multiple discrete operations into a continuous automated process, eliminating transitions between separate machines or manual steps, thereby improving productivity while managing system complexity through integration.
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 system significantly reduces labor costs and increases efficiency by enabling precise and consistent connection of wires to PCBs, thereby lowering the overall manufacturing expense and improving the accuracy of cable assembly production.
Implementation Method 1
The electrical connection is made by processes such as welding, soldering and the like
Implementation Method 2
The electrical connection is made by processes such as welding, soldering and the like
Data Source
AI summary
An apparatus for manufacturing cable assemblies includes one or more wire sources, multiple grippers, a circuit-board handler and a joining tool. The wire sources are configured to supply a continuous set of wires. The grippers are configured to grip the wires and successively draw predefined lengths of the wires from the wire sources. The circuit-board handler is configured to place a respective circuit board against each predefined length of the wires held by the grippers. The joining tool is configured to connect each circuit board to an end of the corresponding predefined length of wires.