Sealant-Coated Connector Assembly for Precise Drill-and-Insert Joining
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Solution Overview
Problem
Automated assembly processes for connecting components lack optimization in individual work steps and tool adaptation, leading to potential improvements in stability, reproducibility, and quality control.
Innovation Solution
A sealant application station and assembly tool system that applies sealant to connectors using a gripper and drive unit for rotational application, combined with an assembly tool for precise connector placement and drilling, allowing for improved connection quality and reduced mechanical complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual assembly processes are replaced by automated assembly processes, then quality and reproducibility are improved, but the complexity of the automated system increases
Solution Approach 1:
The automated assembly system is divided into separate functional modules: a sealant application station with rotary gripper for sealant application, and a separate assembly tool for connector insertion. This segmentation allows each module to be optimized independently while maintaining overall system reliability and reducing total system complexity.
Solution Approach 2:
The sealant application station with the rotary gripper is designed as a universal module that can apply sealant to different types of connectors through rotational positioning. The gripper can hold and rotate various connector types, making the equipment adaptable to multiple assembly tasks without requiring complete system redesign.
2Loss of time
If automated assembly processes are implemented, then lead time is reduced, but the mechanical complexity of tools increases
Solution Approach 1:
The gripper is designed with dynamic rotational capability driven by a drive unit, allowing it to rotate to different positions for sealant application. This dynamic rotation replaces complex multi-axis positioning mechanisms, reducing mechanical complexity while maintaining fast and precise sealant application timing.
Solution Approach 2:
The sealant is applied to the connector in advance during the rotary gripper operation before the connector is inserted into the workpiece. This preliminary sealant application ensures that the connector is already sealed when inserted, reducing assembly time and eliminating the need for post-assembly sealing operations.
3Manufacturing precision
If sealant is applied during connector insertion, then connection quality is improved, but the complexity of the assembly tool increases
Solution Approach 1:
The system separates sealant application and connector insertion into two distinct functional units: the sealant application station with rotary gripper, and the assembly tool for insertion. This segmentation allows each tool to be simpler in design while achieving high connection quality through coordinated operation.
Solution Approach 2:
The rotary gripper acts as an intermediary device that receives connectors, applies sealant through rotation, and then transfers the sealed connectors to the assembly tool for insertion. This intermediary function ensures precise sealant application without requiring the assembly tool itself to have complex sealant application mechanisms.
Data Source
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AI summary
An assembly system (1) comprising a sealant application station (200) and an assembly tool (300) is described. The assembly system serves to join two or more components (400A, 400B) together. The sealant application station (200) applies a sealant to a connector (215). The sealant application station is arranged in a feed system (101, 201) for the connectors. The connectors (215) coated with sealant are transferred to the assembly tool (300). The assembly tool (300) contains a drill spindle (311) in which a connector (215) and a drill bit (315) can be axially aligned with each other so that the drill spindle (311) can, with a linear movement along a machining axis (319), both drill a hole in the components to be joined and position the connector (215) in the drilled hole.For these work steps, the drill spindle (311) moves only along the machining axis (319), so that a linear drive can be used for these work steps.