Precision Engineering for Complex Automation

Introduction: Ultra‑thin wires need to be connected to circuit boards using pins, but the process is challenging because the surface coating needs to be removed during the process. Previously, this was a manual process and the quality of the connection depended on the operator's skill and consistency. This led to issues with quality, speed, and a high rejection rate.

Problem: The manual process of connecting ultra‑thin wires to circuit boards using pins was prone to errors and inconsistencies, resulting in a high rejection rate and reduced efficiency. The quality of the connection depended on the operator's skill and attention to detail, which was difficult to maintain consistently.

Solution: To address these issues, I created a machine that used precise pressure to make consistent pressing results. The machine was designed to handle the ultra‑thin wires and circuit boards with care, ensuring a high‑quality connection every time. The machine was also able to work faster than a manual process, improving efficiency and reducing the rejection rate.

Results: The precision pressing machine was a huge success. It improved the quality of the ultra‑thin wire connections, increased the speed of the process, and significantly reduced the rejection rate. In addition, it eliminated the need for skilled operators, making the process more reliable and consistent.

Introduction: In our production process, workpieces need to dip into a special solution multiple times to achieve a specific thickness. However, the number of dips is temperature, timing, and humidity dependent, making it difficult to achieve high accuracy measurements manually. We needed a solution that would allow us to make real‑time high accuracy measurements to ensure the quality of the final product and adjust the dipping action parameters accordingly.

Problem: Manually measuring the thickness of the workpieces after dipping them into the special solution was a challenging task due to the variability of the process. It was difficult to maintain consistent accuracy, leading to issues with quality control and production efficiency.

Solution: To overcome these challenges, I implemented a solution using two robots, two Keyence optical micrometers, and a heat tunnel. The robots were able to handle the workpieces with precision, while the optical micrometers provided high accuracy measurements. The heat tunnel ensured consistent temperature and humidity conditions during the process. With real‑time measurement data, I was able to adjust the dipping action parameters based on the measurements and achieve the desired thickness more consistently.

Results: The machine allowed us to make real‑time high accuracy thickness measurements and adjust the dipping action parameters accordingly, ensuring the quality of the final product. The use of robotics and optical micrometers also improved production efficiency and eliminated the need for manual measurement methods.

Introduction: This manufacturing process requires to move many workpieces from one solution to the next, with each workpiece staying in different solutions for different periods. The process was originally handled by operators, but it was very slow, ineffective, and easy for them to make mistakes. I was asked to provide a solution that would improve the production rate and reduce the risk of mistakes.

Problem: Manually moving the workpieces from one solution to the next was a slow and inefficient process. It was difficult for operators to keep up with the production rate and there was a high risk of mistakes being made.

Solution: To overcome these challenges, I implemented a solution using a gantry robot. I optimized the sequence to significantly increase the production rate and reduce the risk of mistakes. The gantry robot was able to move the workpieces from one solution to the next with precision and speed, improving the efficiency of the process.

Results: The solution I implemented was a huge success. The use of the gantry robot significantly increased the production rate and reduced the risk of mistakes. It allowed me to meet my production goals more efficiently and effectively.

Introduction: The team needed a solution to efficiently schedule the arrangement of thousands of boxes and fixtures daily, while also integrating with a Nikon X‑ray machine for 3D scanning of dental impressions. The goal was to minimize downtime for the X‑ray machine.

Problem: Manually scheduling the arrangement of boxes and fixtures was a time‑consuming and error‑prone process. It was also difficult to integrate with the Nikon X‑ray machine for 3D scanning, leading to frequent downtime for the machine.

Solution: To overcome these challenges, I developed a customized machine that uses a conveyor system and robot to streamline the scheduling process. The machine is able to work in conjunction with the Nikon X‑ray machine to scan and arrange dental impressions for 3D scanning, minimizing downtime for the machine.

Results: The customized machine has been a great success. It has significantly improved the efficiency and accuracy of the scheduling process, while also minimizing downtime for the Nikon X‑ray machine.