Unified Vacuum-Ultrasonic Tool Head for Robotic Part Handling
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Solution Overview
Problem
Current robotic manufacturing systems lack the control and dexterity to be cost-effectively implemented in various manufacturing processes, and traditional automation relies on discrete mechanisms for each process, leading to inefficiencies in production and costs.
Innovation Solution
A unified manufacturing tool combining a vacuum tool and an ultrasonic welder, allowing for the picking, positioning, and welding of parts with a single positional member, which is adaptable to various materials, shapes, and sizes, and can be manipulated by a robot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete mechanisms are used for each manufacturing process, then each process can be performed with dedicated equipment, but production efficiency decreases and costs increase
Solution Approach 1:
The patent combines multiple discrete manufacturing functions (pickup, positioning, welding) into a single integrated tool head. The vacuum pickup mechanism and ultrasonic welding mechanism are merged into one device that can perform both functions sequentially without requiring tool changes or multiple separate mechanisms, thereby improving productivity while maintaining ease of manufacture for each individual function.
Solution Approach 2:
The tool head is designed with universal multi-functionality, capable of performing pickup operations via vacuum mechanism and welding operations via ultrasonic mechanism. This single positional member can adapt to different manufacturing tasks by switching between functions, eliminating the need for multiple dedicated mechanisms and improving overall production efficiency.
2Ease of manufacture
If multiple discrete tools are used for pickup and welding, then each function can be optimized independently, but device complexity and cost increase
Solution Approach 1:
The patent merges the vacuum pickup tool and ultrasonic welding tool into a single integrated device. Both mechanisms share common components such as the positional member, mounting interface, and control system, reducing overall device complexity while allowing each function to be independently optimized through modular design of the vacuum mechanism and ultrasonic mechanism.
3Ease of operation
If human hand or simple robotic means are used for part handling, then implementation is straightforward, but control and dexterity are insufficient
Solution Approach 1:
The patent replaces simple mechanical robotic means with a more advanced integrated system that combines vacuum field-based pickup with ultrasonic vibration-based welding. The vacuum mechanism provides precise control for pickup and positioning, while the ultrasonic mechanism delivers controlled welding energy, significantly improving reliability, control, and dexterity compared to simple robotic grippers.
Solution Approach 2:
The vacuum pickup mechanism utilizes pneumatic principles to achieve reliable part handling. By creating a vacuum field through pneumatic pumps or generators, the system achieves precise control over part pickup and release, providing both ease of operation and high reliability that simple mechanical systems cannot match.
4Productivity
If a unified tool is used for multiple functions, then productivity and flexibility improve, but manufacturing complexity of the tool increases
Solution Approach 1:
The unified tool head is segmented into distinct functional modules: a vacuum pickup mechanism module and an ultrasonic welding mechanism module. Each module can be independently designed, manufactured, and maintained, which manages the complexity of the overall tool while enabling multi-functionality. The segmentation allows the tool to achieve high productivity through integrated operations without overwhelming manufacturing complexity.
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
This solution enhances the adaptability and efficiency of manufacturing processes by enabling precise handling and joining of parts with reduced costs and increased flexibility, improving the overall automation of manufacturing systems.
Implementation Method 1
a vacuum-powered part holder having a bottom surface adapted for contacting a manufacturing part
Implementation Method 2
an ultrasonic-welding horn... applying ultrasonic energy effective for joining the manufacturing part with another part
Data Source
AI summary
Aspects relate to systems, methods, and apparatus for a manufacturing tool. The manufacturing tool is comprised of a vacuum tool and an ultrasonic welder as a unified manufacturing tool. The manufacturing tool may be used to pick and position a manufacturing part that is then welded with the associated ultrasonic welder.