Rotary Conveyor Connector Insertion with Optical Correction
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Solution Overview
Problem
Existing methods for inserting separate connectors into grooves of building panels lack precision and accuracy, leading to positional deviations and inefficiencies in the assembly process.
Innovation Solution
A method and device that utilize a pressure roller equipped with an optical sensor for precise alignment and correction of connectors, combined with a resiliently mounted application head and rotary conveyor, allowing for impulse-like pressing and accurate positioning of connectors into grooves, with the pressure roller remaining stationary while the device moves perpendicular to the panel feed direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional pressing device is used to insert connectors into grooves, then the insertion process can be completed, but the positional accuracy and precision of connector insertion deteriorates
Solution Approach 1:
The patent replaces conventional mechanical pressing devices with a rotary conveyor system that uses rotational motion to precisely position and insert connectors. The rotary conveyor rotates connectors into the groove while maintaining precise positional control, eliminating the need for complex mechanical positioning mechanisms and achieving high insertion accuracy without increasing device complexity.
Solution Approach 2:
The patent introduces dynamic rotational movement of the conveyor to correct connector positions in real-time during the insertion process. The conveyor can rotate connectors to compensate for positional deviations, enabling dynamic position correction and achieving high manufacturing precision while keeping the overall device structure simple.
2Productivity
If connectors are pre-assembled and aligned in a shaft magazine, then the alignment process is simplified, but the time required for connector preparation and insertion increases
Solution Approach 1:
The patent performs preliminary alignment of connectors on the rotary conveyor before insertion, where connectors are automatically positioned and oriented in the correct direction during the rotation process. This preliminary action eliminates the need for time-consuming manual or mechanical alignment operations, enabling rapid insertion while maintaining high precision through the conveyor's rotational positioning capability.
3Manufacturing precision
If the application head moves back and forth perpendicular to the feed direction, then the insertion process can be completed, but the positional accuracy of connectors deteriorates due to repeated positioning adjustments
Solution Approach 1:
The patent uses the rotary conveyor's dynamic rotation to correct connector positions during the insertion process. Instead of relying on a stationary application head to maintain precision, the rotating conveyor actively adjusts connector positions dynamically, achieving high position repeatability while keeping the operation simple through automated rotational correction.
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
Enables accurate and repeatable insertion of connectors with positional deviations minimized to ±5.0 mm over a 2.5 m panel length, allowing for efficient and precise assembly without pre-assembling connectors, and accommodating connectors of complex profiles.
Implementation Method 1
The pressure roller can be equipped with at least one optical sensor, with which the connectors driven into the grooves can be scanned.
Implementation Method 2
the connectors in addition to the force of the application head a movement is conveyed by means of a slide which is resiliently arranged on the application head and exerts an impact force
Data Source
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AI summary
The method involves aligning building panels by temporarily holding connector (22) picked up by rotary conveyor (8) in longitudinal edge parallel to feed direction. The connector is successively removed from rotary conveyor along direction perpendicular to feed direction of back and forth movable application head and is sequentially pressed into grooves of the pre-run building panels. The rotary conveyor is rotated at predetermined angle corresponding to the position next to a peripheral of the rotary conveyor, and the connector is inserted into a groove. An independent claim is included for device for an automatic sequential insertion of separate connectors in grooves of building panels.