Rotary Disc Assembly for Flexible Light Guide Positioning

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Solution Overview

Problem

Manual assembly of small form-factor pluggable modules and components is inefficient and prone to errors, especially with the miniaturization trend, and flexible light guides pose challenges in automatic assembly due to twisting and deformation.

Innovation Solution

An automatic assembling system featuring a mechanical arm with a rotary disc and multiple gripping devices, a pressing tool, and a visual inspection device, which allows for precise alignment and assembly of various components, including flexible light guides, on an assembly table, reducing manual intervention and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual operation is used for assembling housing and components, then flexibility in handling various components is maintained, but production efficiency is low and errors occur easily

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmanual operation

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The system enables automatic self-assembly through the mechanical arm that autonomously picks up components, positions them, and secures them to the housing without human intervention, resolving the contradiction between automation and efficiency

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical assembly with an automated mechanical arm system equipped with gripping devices and pressing tools, eliminating manual labor while maintaining precise component handling capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If a general automatic assembling system is developed, then productivity is improved, but device complexity increases due to accommodating many kinds of electronic modules

Engineering Contradiction:

Improveassembling efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The mechanical arm is designed with multiple gripping devices and adjustable pressing tools that can handle various types of electronic modules and components, enabling one system to perform multiple assembly functions without requiring separate specialized equipment for each module type

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system incorporates adjustable and reconfigurable gripping devices that can adapt their configuration based on the specific component being assembled, allowing the same mechanical structure to accommodate different module types through dynamic adjustment rather than fixed specialized designs

Inventive Principle:

Principle #15Dynamics

3Volume of moving object

If miniaturization of modules is pursued, then product size is reduced, but assembling precision requirements increase making accurate picking and assembly problematic

Engineering Contradiction:

Improvemodule sizeVSAvoidassembling precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent replaces manual assembly with an automated mechanical arm system that provides consistent, precise positioning and placement of miniaturized components, eliminating human error and variability while maintaining the ability to handle small components through controlled mechanical motion

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses visual guidance technology to create a digital representation or model of the target position and orientation for each component, allowing the mechanical arm to accurately replicate the required placement position even for miniaturized components with tight tolerances

Inventive Principle:

Principle #26Copying

4Ease of manufacture

If flexible light guide is mounted on housing, then optical functionality is achieved, but the light guide may be twisted and deformed adversely influencing the assembling process

Engineering Contradiction:

Improveassembly easeVSAvoidlight guide stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent introduces a positioning fixture or guide structure that acts as an intermediary between the mechanical arm and the flexible light guide, providing a stable reference framework that prevents twisting and deformation while allowing the light guide to be properly positioned and secured

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system applies preliminary positioning and constraint actions to the flexible light guide before final assembly, using positioning fixtures to prevent twisting and deformation in advance, thereby eliminating the need for corrective actions later in the assembly process

Inventive Principle:

Principle #9Preliminary anti-action

Data Source

PatentUS11090774B2Automatic assembling system and method

Publication Date: 2021.08.17 TYCO ELECTRONICS (SHANGHAI) CO LTD

AI summary

An automatic assembling system has a component tray, an assembly table, a mechanical arm and pressing tool. The mechanical arm includes a rotary disc and a plurality of gripping devices mounted on the rotary disc, wherein the rotary disc is configured to rotate about an axis such that one of the plurality of gripping devices is aligned with a corresponding component disposed on the component tray and grips the corresponding component. The pressing tool is also mounted on the rotary disc and is configured to press and/or adjust an assembled component on the assembly table.