Vision-Guided Washer Insertion for Faster Molded Part Assembly
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Solution Overview
Problem
Current assembly processes for molded products with mechanical fasteners are slow, labor-intensive, and pose safety risks due to manual insertion of washers and other fasteners, increasing costs and processing time.
Innovation Solution
An automated insertion system with a frame, motors, and actuator assemblies that move an insertion assembly along X, Y, and Z axes to precisely align and insert fastener components into molded parts, reducing manual labor and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used to place and press washers into molded parts, then flexibility and simplicity are maintained, but assembly time and labor costs increase significantly
Solution Approach 1:
The system uses vision sensors to automatically detect washer positions and receiver locations, eliminating the need for manual alignment. The controller autonomously plans insertion paths and coordinates robotic movements, enabling the system to self-manage the complex task of multi-washer insertion without human intervention.
Solution Approach 2:
Manual mechanical operations are replaced with an automated robotic system comprising robotic arms, grippers, and programmable controllers. This substitution transforms labor-intensive manual placement and pressing into automated mechanical operations, dramatically increasing assembly speed while managing complexity through integration.
2Manufacturing precision
If multiple washers are inserted using manually operated presses, then each component can be precisely positioned, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The system performs multiple washer insertions in continuous sequence without manual intervention between operations. The robotic arms coordinate their movements continuously, with each washer being picked, positioned, and pressed in an unbroken workflow, eliminating idle time between individual operations while maintaining precision through automated control.
Solution Approach 2:
The vision system performs preliminary detection and localization of washers and receivers before the insertion process begins. The controller pre-plans insertion paths and sequences based on detected positions, allowing the robotic system to execute precise positioning operations without time-consuming manual alignment for each washer.
3Ease of operation
If manual operators repeatedly insert fasteners into molded parts, then adaptability to different positions is maintained, but safety risks and labor costs increase
Solution Approach 1:
The system autonomously adapts to different washer and receiver configurations through vision-based detection and automated path planning. The controller self-adjusts insertion sequences and robotic movements based on detected positions, eliminating the need for manual operators to repeatedly position themselves in potentially hazardous areas while maintaining full operational flexibility.
Data Source
AI summary
An automated insertion system for inserting or combining one or more fastener components with a molded part. The automated insertion system can handle multiple fastener components repeatedly, and do so faster and more safely than current processes.