Wire Assembly Recombination to Cut Material Loss and Preserve Geometry
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Solution Overview
Problem
Existing methods for manufacturing final assemblies using metal wire elements result in material loss and fail to achieve desired geometric and mechanical properties, especially when split assemblies are not identical, leading to inefficiencies and suboptimal performance.
Innovation Solution
A method involving the use of transient cores for preforming metal wire elements, followed by a reassembly process to form identical final assemblies, where the wire elements are wound in helices with consistent diameter and pitch, allowing for the reuse of metal wire elements and achieving desired geometric characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the prior art process splits transient assemblies into fractional assemblies, then the manufacturing process can produce final assemblies, but material loss occurs when the fractional assemblies are not identical
Solution Approach 1:
The patent combines multiple fractional assemblies (AF11, AF21) that were previously discarded into a single final assembly. By merging these fractional assemblies containing wire elements with identical geometric characteristics, the process recovers material that would otherwise be lost, directly reducing material waste while maintaining manufacturing efficiency
Solution Approach 2:
The patent recovers wire elements from fractional assemblies that were previously discarded. By identifying and separating wire elements with identical geometric characteristics from different transient assemblies, the process recovers valuable material instead of discarding it, converting waste into usable components for final assemblies
2Manufacturing precision
If a large number of metallic wire elements are used in the transient assembly, then the desired geometric characteristics can be achieved, but the device complexity increases
Solution Approach 1:
The patent segments the transient assembly into multiple fractional assemblies with identical geometric characteristics. By dividing the large transient assembly into smaller, manageable fractional units (AF11, AF21, etc.), the process maintains geometric precision while reducing the complexity of individual assemblies that need to be handled and processed at any one time
Solution Approach 2:
The patent ensures that each fractional assembly contains wire elements with identical local geometric characteristics (diameter, pitch, helix diameter). This local uniformity within each fractional assembly allows for precise manufacturing while the overall system manages complexity through standardization of these local properties across multiple fractional units
3Ease of manufacture
If mechanical tools are used for preforming wire elements, then the process can shape the wire elements, but the mechanical properties of the final assemblies are reduced
Solution Approach 1:
The patent uses a transient core as an intermediary object around which wire elements are naturally formed into helical shapes. Instead of using mechanical tools to force-shaped the wire, the transient core serves as a passive form around which the wire self-organizes, preserving the wire's mechanical properties while achieving the desired helical geometry
Solution Approach 2:
The wire elements self-form into helical shapes around the transient core without external mechanical intervention. The wire's own elasticity and flexibility allow it to naturally conform to the core's geometry, eliminating the need for mechanical preforming tools that would damage the wire's mechanical properties
Data Source
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AI summary
The method makes it possible to manufacture, first, second and third identical final assemblies (A1, A2, A3). The method comprises steps (210, 210') of providing first and second transitional assemblies (AT1, AT2), a step (124) of separating the first transitional assembly (AT1) between a first split assembly AF11 and a second split assembly AF12 forming the second final assembly (A2), a step (224') of separating the second transitional assembly (AT2) between a first split assembly AF21 and a second split assembly AF22 forming the third final assembly (A3), and a step (234) of reassembling the first split assembly AF11 with the first split assembly AF21 so as to form the first final assembly (A1).