Automated Assembly Machine for Disposable Syringe-Driven Filter
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Solution Overview
Problem
The current production of disposable syringe-driven filters is semi-automatic, leading to increased production time, labor intensity, and a high incidence of defective products due to manual handling and incorrect placement of components.
Innovation Solution
An automated assembly machine with a rack, automatic controller, rotating table, and mechanisms for automatic loading, sucking, and unloading of components, including guiding rails and sliding blocks, enables the automatic assembly of disposable syringe-driven filters, ensuring precise placement and mounting of the upper and lower covers and filter discs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used for disposable syringe-driven filter production, then device complexity is reduced, but productivity decreases and manufacturing precision deteriorates
Solution Approach 1:
The assembly machine is divided into multiple independent functional modules including a first loading mechanism for lower covers, a filter disc loading mechanism, a second loading mechanism for upper covers, and an unloading mechanism. Each module operates independently on the rotating table, allowing parallel processing and improving overall productivity while keeping individual module complexity manageable.
Solution Approach 2:
The rotating table serves as a universal platform that coordinates all loading and assembly operations. It provides a common workspace that accommodates multiple mechanisms simultaneously, enabling the system to handle different components (lower covers, filter discs, upper covers) through a single integrated structure rather than requiring separate dedicated equipment for each operation.
2Manufacturing precision
If manual placement of filter disc is used, then device complexity is reduced, but manufacturing precision deteriorates due to incorrect positioning
Solution Approach 1:
The filter disc loading mechanism replaces manual mechanical placement with an automated suction-based system. The mechanism uses suction force to grasp and position the filter disc precisely on the lower cover, eliminating human error in positioning while the guiding rails provide mechanical constraints to ensure accurate alignment during the automated process.
Solution Approach 2:
The filter disc loading mechanism acts as an intermediary between the filter disc source and the lower cover assembly point. It includes components like suction cups and guiding rails that mediate the transfer process, ensuring the filter disc is correctly oriented and positioned before being placed on the lower cover, thereby improving positioning accuracy.
3Loss of time
If semi-automatic production with manual carrying is used, then device complexity is reduced, but loss of time increases due to extended turnover time
Solution Approach 1:
The machine merges multiple previously separate operations (loading lower covers, loading filter discs, loading upper covers, and unloading assembled products) into a single integrated automated system. All these operations occur on one rotating table platform, eliminating the need to manually carry components between different workstations and significantly reducing production turnover time.
Solution Approach 2:
The rotating table enables continuous operation by maintaining all loading and assembly mechanisms in constant readiness. As one station completes its operation, the table rotates to bring the next station into position, ensuring that useful action continues without interruption. This eliminates idle time and waiting periods associated with manual carrying and setup changes.
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 significantly reduces production time, increases productivity, and minimizes defective products by ensuring accurate and efficient assembly of disposable syringe-driven filters.
Implementation Method 1
an automatic filter disc-sucking mechanism... a filter disc-sucking guiding rail is arranged within the automatic filter disc-sucking mechanism
Data Source
AI summary
An assembly machine for assembling disposable syringe-driven filter is provided, which includes a rack and an automatic controller arranged on the rack. The automatic controller is electrically connected with a rotating table, a first automatic loading mechanism, an automatic filter disc-sucking mechanism, a second automatic loading mechanism, and an automatic unloading mechanism. Using the first and second automatic loading mechanisms, the automatic filter disc-sucking mechanism, and the automatic unloading mechanism, as well as the automatic controller, the assembly machine can realize the automatic loading of the upper cover of a disposable syringe-driven filter, the automatic placing of filter disc, the automatic loading and assembling of the lower cover of filter and the automatic unloading of the disposable syringe-driven filter, so that the automatic production of the disposable syringe-driven filter can be realized.