Robotic Hot Knife Joining for Precise Wax Mold Assembly

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Solution Overview

Problem

The manual process of assembling wax molds for lost wax casting is labor-intensive, time-consuming, and prone to variations, making it challenging to achieve precise accuracy and consistency in the assembly process.

Innovation Solution

An automated system using a robotic arm equipped with a hot knife having a removable blade, mounted on a quick change tool, to perform knife joining operations, ensuring precise and consistent weld joints in the assembly of wax molds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual assembly process is used, then flexibility and adaptability are maintained, but labor intensity increases and assembly precision decreases

Engineering Contradiction:

Improveassembly precisionVSAvoidautomation level

Core Design Contradiction:

Manufacturing precisionVSExtent of automation

Solution Approach 1:

The patent replaces manual mechanical assembly operations with an automated robotic system that uses a heated tool to join wax pattern components. The robot arm executes programmed movements to position and heat the wax parts, eliminating manual labor while maintaining precision through automated control systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces controlled thermal parameters by heating the joining tool to specific temperatures to melt and fuse wax components. This temperature control parameter enables precise joining operations that are difficult to achieve manually, improving assembly precision through thermally-assisted automated joining.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If manual welding process is used, then operational flexibility is maintained, but consistency and quality control deteriorate

Engineering Contradiction:

Improveweld quality consistencyVSAvoidautomation system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual welding operations with an automated robotic system that consistently applies heat and pressure to join wax components. The automation ensures uniform weld quality across all joints by eliminating human variability in technique and application, though it requires programming and control systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated system incorporates control mechanisms that monitor and regulate the welding process parameters, ensuring consistent weld quality. The robotic arm follows programmed trajectories and the heating process is controlled to maintain reliability across multiple welds.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If multiple hot knife tip sizes are used, then versatility is improved, but orientation consistency and repeatability worsen

Engineering Contradiction:

Improveknife tip varietyVSAvoidknife orientation precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent employs a single automated robotic tool that can perform multiple welding functions by adjusting its movement patterns and heating parameters. The robotic system achieves versatility through programmable operations rather than multiple physical knife tips, maintaining consistent orientation through automated control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The automated system dynamically adjusts its operation parameters including heating temperature, contact time, and movement speed to handle different welding scenarios. This dynamic control provides versatility without sacrificing orientation precision, as the robot maintains consistent positioning through programmed trajectories.

Inventive Principle:

Principle #15Dynamics

4Productivity

If manual inspection process is used, then flexibility in verification is maintained, but inspection time and labor requirements increase

Engineering Contradiction:

Improveinspection efficiencyVSAvoidinspection automation

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The patent replaces manual inspection operations with automated visual inspection systems that verify weld quality and pattern assembly. The automation reduces inspection time and labor requirements by continuously monitoring the welding process and final product quality without requiring manual intervention for each component.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides consistent and high-quality weld joints, reduces labor and technical skill requirements, and minimizes defects by ensuring precise control over the hot knife's position and contact time with the wax.

Implementation Method 1

The blade is heated to a temperature sufficient to melt the wax material at the contact point

Methodology Applied

Scientific EffectConduction (thermal): Conduction (thermal)

Implementation Method 2

melt the wax material at the contact point, thereby joining the mold parts together

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS12208440B2Method and device for welding tool automation

Publication Date: 2025.01.28 CANON VIRGINIA INC

AI summary

The present disclosure relates to a hot knife having a removable blade or tip that has been specifically designed to perform knife joining operations. The knife is mounted to a quick change tool that connects to the end of a robotic arm.