Stacked Component Assembly Using Dual Imaging for Axial Alignment
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Solution Overview
Problem
Existing automated assembly systems for disc-shaped objects, such as coin cells, face challenges in precise alignment and validation of components, leading to misalignment and premature failure, especially when dealing with nonplanar or deformed components, resulting in poor performance and misleading test results.
Innovation Solution
An apparatus comprising a component holder, first and second imaging devices, and a controller that coordinates the component holder and imaging devices to align and validate the position of components using reference alignment features, allowing for automated assembly with axial alignment assurance without operator supervision, and includes image processing for accuracy and defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional automated assembly systems are used, then assembly speed and productivity are improved, but alignment precision and component positioning accuracy deteriorate
Solution Approach 1:
The system performs preliminary imaging and alignment feature detection before the actual assembly operation. The first imaging device captures images of components in the component holder, identifies alignment features, and calculates positioning adjustments in advance, allowing the component holder to place components with high precision without slowing down the assembly process
Solution Approach 2:
The system implements a feedback loop where the first imaging device continuously monitors component positions, the controller adjusts positioning based on detected alignment features, and the second imaging device validates the final placement. This closed-loop feedback ensures high alignment precision while maintaining automated assembly speed
2Manufacturing precision
If operator supervision is implemented, then alignment accuracy is improved, but automation level and productivity deteriorate
Solution Approach 1:
The system performs self-alignment and self-validation operations. The imaging devices automatically detect alignment features on components, the controller autonomously calculates and applies positioning adjustments, and the system self-validates placement accuracy - all without operator intervention, maintaining both high automation and precision
Solution Approach 2:
The system replaces manual operator supervision with an automated optical-mechanical system. The first and second imaging devices, combined with the controller, substitute human visual inspection and manual adjustment with automated image capture, processing, and mechanical positioning, achieving comparable or superior precision while maintaining automation
3Device complexity
If single imaging device is used, then device complexity is reduced, but measurement capability and validation accuracy deteriorate
Solution Approach 1:
The imaging function is segmented into two distinct devices with specialized roles: the first imaging device is optimized for capturing component images in the component holder for alignment feature detection, while the second imaging device is optimized for validating component positions in the assembly zone. This segmentation allows each device to be simpler in design while collectively achieving high measurement precision
Solution Approach 2:
The controller acts as an intermediary that processes images from both imaging devices, correlates the alignment features detected by the first device with the position validation from the second device, and integrates this information to achieve accurate component placement. The intermediary processing reconciles data from multiple sources to enhance overall measurement capability
Data Source
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AI summary
There is provided an apparatus (20) for assembling an object having a stacked construction of a plurality of components. The apparatus (20) comprises: a component holder (22) for selectively holding and placing a component; an assembly zone (32) in which the object may be assembled; first and second imaging devices (28,30), the first imaging device (28) positioned to face in an upward direction, the second imaging device (30) positioned to face in a downward direction; and a controller (40) programmed to selectively coordinate the component holder (22) and the first and second imaging devices (28,30) to carry out an assembly operation for assembling components of the object in which: the component holder (22) holds a component over the first imaging device (28); the first imaging device (28) captures an image of the component; the controller (40) identifies a first reference alignment feature of the component from the image captured by the first imaging device (28); the component holder (22) places the component on top of another component in the assembly zone (32) based on the identified first reference alignment feature of the component; the second imaging device (30) captures an overhead image of the component on top of the other component; the controller (40) identifies a second reference alignment feature of the component from the image captured by the second imaging device (30); the controller (40) validates a position of the component in the assembly zone (32) based on the identified second reference alignment feature of the component.