Vacuum Pull Ring Manipulator for Precise Pull Wire Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual assembly of pull wire assemblies is time-consuming, prone to defects, and physically straining for operators, with components requiring precise positioning for reliable laser welding.
Innovation Solution
An automated pull wire assembly machine with a robotic arm, vacuum nozzle, and end effector for precise placement and laser welding of pull wires to pull rings, incorporating a vision system for quality control and automated sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly is used with operator careful handling and microscope observation, then assembly precision is improved, but assembly time increases and operator fatigue increases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated robotic system. A robotic arm with vacuum nozzle picks up pull rings and places them in fixtures, while another robotic arm positions pull wires. This automation eliminates manual handling while maintaining precision through controlled robotic movements and vacuum gripping, thereby reducing assembly time and operator fatigue.
2Manufacturing precision
If manual assembly with miniature pliers and microscope is used, then assembly precision is improved, but operator physical strain increases
Solution Approach 1:
The patent replaces manual mechanical operations with automated robotic systems. Robotic arms perform picking, placing, and positioning operations that previously required operators to use miniature pliers and maintain precise positioning under microscope observation. This eliminates physical strain while maintaining positioning precision through automated control.
3Productivity
If automated robotic assembly is implemented, then assembly time is reduced and productivity is improved, but device complexity increases
Solution Approach 1:
The automated assembly system is divided into separate functional modules: a robotic arm with vacuum nozzle for pull ring handling, another robotic arm for wire positioning, a laser welding system, and a vision system. Each module performs a specific function, allowing the complex automation task to be managed through modular components rather than a single monolithic system.
Solution Approach 2:
The patent introduces a vision system as an intermediary between the robotic arms and the assembly process. The vision system captures images, processes them to identify component positions and orientations, and provides feedback to the robotic controllers. This intermediary layer simplifies the overall control by adding sensory capability without requiring complex direct control mechanisms.
4Manufacturing precision
If vacuum nozzle is used to hold pull ring, then handling precision is improved, but risk of damaging small components increases
Solution Approach 1:
The patent uses a vacuum nozzle that creates a vacuum field to hold the pull ring during robotic manipulation. The vacuum force distributes pressure across the pull ring surface, providing secure holding without concentrated mechanical contact points that could damage the small, delicate components. The vacuum pressure can be precisely controlled to match the weight and surface characteristics of the pull ring.
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 assembly process is automated, reducing assembly time, minimizing defects, and alleviating operator strain while ensuring high-quality and efficient production of pull wire assemblies.
Implementation Method 1
The vacuum ports create a vacuum in the vacuum chamber to hold the pull ring in the vacuum chamber
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A ring manipulator (304) for a pull wire assembly machine (100) configured to assemble a pull wire (20) to a pull ring (30) is provided. The ring manipulator includes a robotic arm (320) that includes a mounting base (330) and link arms (332) attached to the mounting base and to each other at joints (334). The robotic arm is movable in three-dimensional space. The robotic arm has a distal end (324). The ring manipulator includes an end effector at the distal end of the robotic arm. The end effector (322) includes a vacuum nozzle (342) includes a vacuum chamber (362) and vacuum ports (366) in the vacuum chamber. The vacuum chamber configured to receive the pull ring. The vacuum ports create a vacuum in the vacuum chamber to hold the pull ring in the vacuum chamber.