Automated T-nut Installation Apparatus for Flat Substrates
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Solution Overview
Problem
Existing T-nut insertion machines pose safety risks due to misuse, leading to injuries and high employee turnover rates, and are inefficient in maintaining consistent production rates.
Innovation Solution
An automated insertable fastener installation apparatus that eliminates the need for manual operation by using a conveyor system, optical vision, and robotic placement of T-nuts into substrates, ensuring safety and reducing labor requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation of T-nut insertion machines is used, then the machine can be operated with simple controls, but operator safety is compromised due to misuse and bypassing of safety features
Solution Approach 1:
The patent replaces the manual mechanical operation system with an automated robotic system that uses vision guidance and programmable control. The robotic arm performs T-nut insertion automatically, eliminating the need for operators to manually position components and activate safety switches, thereby resolving the contradiction between operational simplicity and safety risks.
2Adaptability or versatility
If manual operation with multiple employees is used, then flexibility in handling different production scenarios is maintained, but employee turnover rates are high and production consistency is poor
Solution Approach 1:
The automated system performs all T-nut insertion operations autonomously without requiring human operators during the insertion process. The robotic system self-regulates its operations, maintains consistent insertion depth and positioning, and eliminates variability introduced by different operators, thereby achieving both reliability and adaptability through programmable control.
3Object-affected harmful factors
If automated robotic insertion is implemented, then operator safety is improved and labor is reduced, but the device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functionality, integrating vision guidance, precision positioning, and automated insertion capabilities into a single platform. This universal system can handle various T-nut sizes and substrate types through programmable control, managing the complexity through consolidation of functions rather than separate dedicated machines for each operation.
4Productivity
If multiple employees operate T-nut machines, then labor costs are higher and training requirements increase, but the machine can handle varied production demands
Solution Approach 1:
The patent extracts the human labor element from the T-nut insertion process by implementing a fully automated robotic system. This eliminates the need for multiple employees, their training, and labor management complexities, while maintaining or improving productivity through consistent automated operation and reduced downtime associated with employee turnover and training.
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 apparatus significantly enhances operator safety, reduces labor, and stabilizes production rates by automating the T-nut installation process, minimizing the risk of injury and maintaining consistent production with fewer operators.
Implementation Method 1
The metal surface of the first roller is spaced apart from the metal surface of the second roller by a gap therebetween. The size of the gap G is less than the thickness of the substrate thus compressing the substrate as it is fed into and through the roller station.
Implementation Method 2
The first and second rollers rotate in opposite directions when viewed along the axes of the rollers. The first roller, viewed from the left side of the apparatus, rotates in a counterclockwise direction. The second roller, viewed from the left side of the apparatus, rotates in a clockwise direction.
Data Source
AI summary
An insertable fastener installation apparatus for a flat substrate has a thickness, T. A roller press station is used to press T-nuts into holes in the substrate. An optical vision system detects the location of the holes in the moving substrate and aligns the t-nuts with the holes. A computer controlled pick and place robot takes T-nuts from an escapement of a hopper feed system and aligns, but does not fully insert, the t-nuts in the substrate. A conveyor system feeds the substrates through the optical vision system, the pick and place robot station and the roller press station. A first roller is spaced apart from a second roller by a gap in the roller press station and the gap is less than the thickness of the substrate. The hopper feed system includes a bulk hopper, a bowl, a track and an escapement.