Description:Field of Invention:
The current invention relates to a machine for manufacturing Liquid Mosquito Destroyer or Mosquito Repellent Liquid Vaporiser. More particularly, the current invention relates to a fully automated machine for manufacturing Liquid Mosquito Destroyer and the assembly line thereof.

Background of Invention:
Liquid Mosquito Destroyers (abbreviated as “LMD”) or Mosquito Repellent Liquid Vaporiser (herein abbreviated as “MLV”) are machines which are required to vaporise a mosquito repellent liquid contained in a container.

The LMD’s work on principle of Electrical Heating. Accordingly, the machine heats up mosquito repelling liquid to create vapours that are dispersed in air. Conventionally, A wick, made up of porous to semi-porous material, which is capable of capillary action brings the liquid to a heating block. The liquid reaching the heating block is instantly evaporated and dispersed in air. The vapours reach to all the corners of room and form a barrier against mosquitoes.

A LMD consists of more than 30 various big and small parts. Traditionally, these parts were assembled manually over a linear conveyer at approx. 10 stations. These components of LMD are sensitive to heat, static charge & handling. Consequently, the process requires a lot of manpower, approx. 80 people were used in the process. As a result of extensive manual labour requirements, there is a greater chance of human error, leading to a sub-standard product.

Therefore, to overcome the problems of prior art, various inventors have tried to develop automatic assemblies for manufacturing the LMD. For instance, CN106219474 (CN ‘474) suggests a mosquito repellent liquid auto-filling assembly. Accordingly, the machine of CN ‘474 comprises of a plurality of automatic material conveyer belts, an automatic bottle arranging machine, an automatic filling machine, a core filling and core rod pressing all-in-one machine, and a cap gripping and screwing all-in-one machine. The automatic bottle arranging machine, the automatic filling machine, the core filling and core rod pressing all-in-one machine, and the cap gripping and screwing all-in-one machine are sequentially connected through the automatic material conveyer belts. The machine, primarily, appears to only automate the filling of liquid in the bottle and not the whole assembly of the destroyer machine.

One more disclosure could be found in CN113104800 (CN ‘800). Similar to CN ‘474, even CN ‘800 discloses an automated line for filling of repellent liquid in bottles. The automatic efficient pesticide filling production of CN ‘800 comprises of an automatic bottle arranging machine, a high-viscosity filling machine, a capping machine, a cap screwing machine, a cap-free askew cap and aluminium foil-free detection and rejection device, an aluminium foil sealing machine, an ink-jet printing machine, a non-setting adhesive labelling machine and a two-dimensional code online acquisition system which are sequentially arranged along the conveying direction of the production line, and further comprises an automatic case unpacking machine.

Additionally, one more liquid filling assembly has been discussed in CN206033200 (CN ‘200). Similar to CN ‘800, even the assembly of CN ‘200 comprises of comprises a plurality of automatic material conveying belt, an automatic bottle filling machine and an automatic filling machine, which are characterized in that it comprises a core, a mandrel, And the self-sealing machine, the automatic filling machine, the loading core, the crimping rod and the gripper and the gripper are respectively connected with the automatic material conveying belt, And a screw-for-core device is provided between the automatic filling machine and the loading core and the crimping rod, and the ferrule boring device And cap cover, screw cap between the one machine is also equipped with a bottle cap feeding device.

As can be seen from above, all the three prior arts discuss bottle filling machine. The machines of CN ‘474, CN ‘800 and CN ‘200 address the issue of labour-intensive assembly line of filling bottles, to address the danger of accidental contact of human, with the poisonous mosquito repellent liquid.

None of the prior arts discuss an assembly for manufacturing the heating units or LMD device, as such. The heating unit, as such, contains about more than 30 components which are sensitive and require precarious handling and precision to manufacture a standard LMD device. Therefore, it is equally necessary to automate this process of manufacturing LMD devices as well.

Summary of Invention:
Therefore, in view of above, the current invention provides an automated machine for manufacturing LMD devices.

The automated machine for manufacturing LMD uses a combination of robotic arms, multidimensional movement of the arm, high speed high accuracy cameras etc. to assemble these parts into final LMD.

The automated machine of the invention increases productivity, maintains consistent quality, thereby reduces cost of production, by substantially reducing product rejection due to sub-par quality.

Adoption of this invention is quite easy on the floor.

Brief Description of Drawings:
Fig. 1 schematically illustrates various components of the automated machine of the invention.

Fig. 2A and 2B illustrates the LMD device.

Fig. 3A illustrates the back panel of the LMD, in accordance with one of the embodiments.

Fig. 3B illustrates the front panel of the LMD, in accordance with one of the embodiments.

Fig. 3C illustrates the heating block of the LMD, in accordance with one of the embodiments.

Fig. 3D illustrates the pin bridge of the LMD, in accordance with one of the embodiments.

Fig. 3E illustrates the refill holder of the LMD, in accordance with one of the embodiments.

Fig. 3F illustrates the switch knob of the LMD, in accordance with one of the embodiments.

Fig. 3G illustrates the PCB unit of the LMD, in accordance with one of the embodiments.

Fig. 4 illustrates the Station 1 of the automated machine of the invention.

Fig. 5 illustrates the Station 2 of the automated machine of the invention.

Fig. 6 illustrates the Station 3 of the automated machine of the invention.

Fig. 7 illustrates the Station 4 of the automated machine of the invention.

Fig. 8 and 9 illustrate the Station 5 and Station 8 of the automated machine of the invention.

Fig. 10 illustrates the Station 6 of the automated machine of the invention.

Fig. 11 illustrates the Station 7 of the automated machine of the invention.

Fig. 12 illustrates the Station 9 of the automated machine of the invention.

Fig. 13 illustrates the Station 10 of the automated machine of the invention.

Fig. 14 illustrates the Station 12 of the automated machine of the invention.

Fig. 15 illustrates the Station 13 of the automated machine of the invention.

Fig. 16 illustrates the Station 14 of the automated machine of the invention.

Fig. 17 illustrates the Station 15 and Station 16 of the automated machine of the invention.

Fig. 18 illustrates the Station 18 of the automated machine of the invention.

Fig. 18 illustrates the Station 19 of the automated machine of the invention.

Fig. 19 illustrates the Station 20 of the automated machine of the invention.

Detailed Description of Drawings:
The LMD machine of the invention comprises of two main components an assembly wheel (100) and an electrical control panel (200).

The assembly wheel (100) of the invention comprises of about 20 station which are as follows:

A (Station 1) comprises of a Back Cover Hopper (404), which is in seamlessly connected to the Back Cover Feeder (405) through a Back Cover elevator (4041), which feeds the back covers (201) to a Back Cover Feeder (405). A robotic arm, placed at the exit end of the back cover feeder (405) picks the back covers (201) from a conveyer of the back cover feeder (405) by a pneumatic gripper (not shown) powered by a Pneumatic cylinder (403) and places them at indexing position (402) on the assembly wheel (100). The (Station 01) is designated as “Back Cover Placing unit”:

The back panel (201) is then presented to Pin Bridge, Heater & PCB Placing Unit (Station 02). The (Station 02) comprises of Feeding conveyer (501) for transporting an assembled piece (500) containing a pin bridge (206), a Heater or Heating unit (203) and a PCB (208). An operator than manually loads the assembled piece (500) onto a Pallet conveyer (503). The pellet conveyer (503) carries the assembled piece (500) to a pick and place unit (504). The pick and place unit (504) places the assembled piece (500) over the back panel (201) at a precise angel and position at indexing position (505).

The PCB (208) is pre-adorned with the LED indicator (205) and a switch (2041).

The hence adorned back cover (201) with the assembled piece (500) is then presented to (Station 03). The (Station 3) comprises of a Pin Bridge Pressing Unit (301). The unit (301) is configured to press the pin bridge (206) onto the back cover, by a pneumatic cylinder. The unit (301) comprises of a top pneumatic cylinder (3011) configure for pressing the floating joint (3012). The floating joint (3012) in turn presses on the spring (3015). This pressure activates pneumatic cylinders (3014), the pneumatic pressure presses the pin bridge (206) in the back cover (201) at station (3010). Once adequately pressed, the back covers are then presented to (Station 04). The said unit (301) comprises of

(Station 04) is a Heater Pressing station, where a Heater presser (401) presses the Heater (203) onto the back cover by a pneumatic cylinder. Once the pin bridge (206) and the Heater (203) are pressed onto the back cover the now partially assembled LMD is presented to (Station 05)

(Station 05) is a PCB relocation station which consists of a pneumatic cylinder (801), a floating joint (802), a pair of pneumatic grippers (803) powered by a pneumatic cylinder (804). The lateral movement of the pneumatic grippers (803) is actuated by pneumatic cylinders (805). The (Station 05) is further provided with a shock absorber (806).

The (Station 05) is configured for relocation of the PCB (208) from magnetic PCB restring plate to PCB resting block, outside the fixture, to avoid the hindrance during placing of refill holder (207). The PCB (208) is to be handled in a manner that no static charge is created or attached wires are impacted as either of this will make the PCB non-functional. Accordingly pneumatic grippers (803) clamp the PCB (207). The pneumatic grippers (803) with the PCB (208) are pneumatically pulled up by cylinders (805). The grippers (803) then place the PCB (208) on a PCB resting block.

After relocation of PCB (208), the back cover is presented to (Station 06) which is Refill holder Placing unit. The (Station 06) comprises of a refill holder feeder unit (1001), a pick and place unit (1002), a component picking unit (1004).

Accordingly, bulk quantity of refill holders (207) is fed into Refill Holder Hopper (10011). The refill holders (307) are then transported to Refill Feeder (10013) through an elevator (10012).

The Refill holders (207) are then picked up by the pick and place unit (1002)
The pick and place unit (1002) grips the refill holder (207) and using angular movement places the holder (207) on the back cover (201) at indexing position (1002) on the assembly wheel (100).

The assembly wheel (100) then presents (Station 07) which is Refill holder Pressing and Wire Dressing Unit. The (Station 07) presses the Refill Holder (207) into the back cover (201) and the wire is dressed. The (Station 07) is actuated by three pneumatic cylinders (1101), (1102) and (1103).

The assembly wheel (100) then presents the part to PCB Relocation Unit (Station 08), which is constructionally and functionally similar to (Station 05). The (Station 8) repositions the PCB (207) to original position.

The assembly wheel (100) then presents the part to (Station 09) which is a Positioning of PCB & Wire Dressing Unit. The (Station 09) comprises of a pneumatic gripper (1201), a pneumatic cylinder (1202), a floating joint (1203), a second pneumatic cylinder (1204), a shock absorber (1205). The entire unit is held on a back support (1206).

The (Station 09) is configured to relocate PCB (208) from resting plate to refill holder (207). Once the PCB (208) is placed at its intended position, the wire is dressed by a pneumatic cylinder and the assembly wheel (100) than presents the component to (Station 10)

(Station 10) is a designated as Knob Correcting, Ionization and Wire Dressing Unit. At this station, when the component is received, PCB (208) is ionised by an ionisation unit (not shown) and the knob position is corrected, as required. Once the ionisation and knob positioning is done the component is than presented to (Station 12).

The assembly wheel (100) then presents the part to (Station 12) which is a switch knob placing unit. At (Station 12) a switch knob is placed over the part. The switch knobs are fed through feeder wheel (1401). A camera (1402) checks the orientation of switch knob and pick and place unit (1403) places the sub assembly at indexing position (1404) on assembly wheel (100).

The assembly wheel (100) then presents the sub assembly to a top cover placing unit (Station 13). The (station 13) is fed top covers (202) through a feeder unit (1501). A robotic pick and place unit (1504) grips the top cover and places on sub assembly at indexing position (1505) on assembly wheel (100). A camera (1503) checks for proper alignment of the top cover (202).

The assembly wheel (100) then presents the sub assembly to a Component Tilting unit (Station 14). The component tilting unit (Station 14) rotates the component by 180 degrees from outside fixture to inside fixture for next Processing.

Accordingly, a pneumatic gripper (1603) picks up the component from the resting block. The component is than rotated by 180° by a rack and pinion type mechanism (1604) actuated by a pneumatic cylinder (1602)

Screw tightening (Stations 15 and 16), respectively tighten screw on Left hand side followed by tighten screw on Right hand. The screws are fed to screw tightening stations 15 and 16 by screw feeding unit (1701) via a screw feeding track (1702). The LH and RH screws are tightened by a screw transfer unit (1703).

The assembly is presented to (Station 18) for electrical and visual inspection of Assembled part. Overall dimensions are inspected by a distance sensor. contact Pin bridge through electrical probe powered by pneumatic cylinder (1801), switch knob actuated by bottom pneumatic cylinder (1803), led light is checked by Camera. The tested units are then presented to Laser marking (station 19) through indexing position (1802).

A Laser Marking (Station 19) is configured for Laser marking by fibre laser marking unit.

Finally, the assembly is presented to Ok NG Pick & Place Unit (Station 20) whereby the assembly is finally examined and packed. The (Station 20) comprises of a OK and NG pick and place unit (2001) which is a robotic arm configured to pick the component from indexing position (2004). The pick and place unit (2001) assess the component, if the assessment is OK, the unit (2001) places the component on OK part conveyer (2002), which transports the OK component to packaging. Else, the component is dumped in NG bin, form where the components may be recycled.

Detailed Description of the Invention:
The invention will now be described in detail in connection with certain preferred and optional embodiments, so that various aspects thereof may be more fully understood and appreciated. However, any skilled person will appreciate the extent to which such embodiments could be extrapolated in practice.

Unless specified otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art, to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described.

Unless stated to the contrary, any of the words “contains”, “containing”, “including,” “includes,” “comprising,” and “comprises” mean “including without limitation” and shall not be construed to limit any general statement that it follows to the specific or similar items or matters immediately following it. Embodiments of the invention are not mutually exclusive but may be implemented in various combinations. The described embodiments of the invention and the disclosed examples are given for the purpose of illustration rather than limitation of the invention.

Further, words like “a”, “an”, “at least” and “the” should be construed to not only cover singular quantities but also plural quantities of the elements immediately following them.

The current invention describes and automated machine for manufacturing of LMD.

Accordingly, in an embodiment, the automated machined essentially comprises of two main components and assembly wheel (100) and an electrical panel (200).

The assembly wheel (100), can also be referred to as “Indexing Table” and each position on the table may be referred to as “indexing position”. The assembly wheel has an approximate diameter of about 1800mm and the same is enclosed in an enclosure measure 4000 mm × 4000mm.

The Indexing Table (100) is adorned by at least 20 stations. Said 20 stations use a combination of robotic arms, cameras etc to assemble the parts into final LMD.

In accordance with above embodiment, the stations are as follows:
(Station 01) is a Back Cover Placing unit configured for placing raw back panels on the assembly wheel (100);
(Station 02) is a Pin Bridge, Heater PCB Placing Unit configured for placing Pin Bridge, Heater PCB over the back panel, wherein, The Pin Bridge, Heater & PCB assembly is a sub unit. This is placed on a specifically designed slat conveyor so that when robotic arms pick all the 3 items together at a particular angle the placement on back cover is automated. The design of the slat conveyor is the technical know-how;
(Station 03) is a Pin Bridge Pressing Unit configured for pneumatically pressing the pin bridge onto the back panel;
(Station 04) is a Heater Pressing station configured for pressing heater onto the back panel;
(Station 05) is a PCB relocation station configured for relocation of PCB from magnetic plate to next magnetic black outside the fixture to avoid the hindrance during refill holder placing;
(Station 06) is a Refill holder Placing unit configured for placing refill holder on rotary fixture on Back cover;
(Station 07) is a Refill Holder Pressing & Wire Dressing Unit configured for pressing the refill holder in back cover and dressing the wire thereof.
(Station 08) is a PCB Relocation Unit for relocating the PCB back to same position during Placing from slat conveyor;
(Station 09) is Positioning of PCB & Wire Dressing Unit configured for transferring PCB (208) from resting plate to refill holder;
(Station 10) is Knob Correcting, Ionization and Wire Dressing Unit which is configured for ionisation of PCB (208) and correcting the knob position.
(Station 11) is a spare station.
(Station 12) is a switch knob placing unit configured for placing switch knob over the subassembly;
(Station 13) is a top cover placing unit configured for placing top cover over the subassembly;
(Station 14) Component Tilting unit configured for titling the component by 180°;
(Station 15 and 16) are screw tightening unit which are configured for tightening the LH and RH screws, respectively.

(Station 17) is a spare station.

(Station 18) electrical and visual inspection for visual and electrical inspection of the LMD. The unit checks the supply of current through pin bridge (206) through electrical probe. The unit further checks the actuation of switch knob (204) by pneumatic cylinder. The unit further visually checks the working of led light (205);

(Station 19) is laser marking unit configured for laser marking of the unit, and

(Station 20) is an Ok NG Pick & Place Unit which shorts the OK component form NG component.

The automated machine according to above embodiment is operated and controlled through the Electric Panel (200).

In accordance with one of the embodiments of the invention the Assembly is a combination of Auto Feeding using Bowl Feeders and Linear feeders., Pick & Place units, Robotic arms for placing and assembly of components, Testing (Visual and Performance), Screwing, Laser Marking and Unloading with segregation of Conforming & Non-Conforming products.

In an advantageous embodiment, this Automated machined is unique in its working due to step conveyor, fixtures, Robotic Arms etc. This will help in increased productivity, consistent quality and hence reduced cost of production. Adoption of this invention is quite easy on the floor.

Claims:

1. An automated assembly machine for manufacturing liquid mosquito destroyer devices, wherein the machine comprises of:
a. a Back Cover Placing unit station 01 configured for placing raw back panels on the assembly wheel (100);
b. a Pin Bridge, Heater PCB Placing Unit 02 configured for placing Pin Bridge, Heater PCB over the back panel placed by the a Back Cover Placing unit station 01 on the assembly wheel (100);
c. a Pin Bridge Pressing Unit (Station 03)configured for pneumatically pressing the pin bridge onto the back panel placed by the station 02 on the assembly wheel (100);
d. a Heater Pressing station (Station 04) configured for pressing heater onto the back panel placed by the station 03 on the assembly wheel (100);
e. a PCB relocation station (Station 05) configured for relocation of PCB from magnetic plate to next magnetic black outside the fixture to avoid the hindrance during refill holder placing placed by the station 04 on the assembly wheel (100);
f. a Refill holder Placing unit (Station 06) configured for placing refill holder on rotary fixture on Back cover placed by the station 05 on the assembly wheel (100);
g. a Refill Holder Pressing & Wire Dressing Unit (Station 07) configured for pressing the refill holder in back cover and dressing the wire thereof placed by the station 05 on the assembly wheel (100);
h. a PCB Relocation Unit (Station 08) configured for relocating the PCB back to same position during placing from slat conveyor of (Station 08);
i. a Positioning of PCB & Wire Dressing Unit (Station 09) configured for transferring PCB (208) from resting plate to refill holder;
j. a Knob Correcting, Ionization and Wire Dressing Unit (Station 10) which is configured for ionisation of PCB (208) and correcting the knob position.
k. a switch knob placing unit (Station 12) configured for placing switch knob over the subassembly placed by the station 10 on the assembly wheel (100);
l. a top cover placing unit (Station 13) configured for placing top cover over the subassembly placed by the station 12 on the assembly wheel (100);
m. a Component Tilting unit (Station 14) configured for titling the component by 180°;
n. screw tightening units (Station 15 and 16) which are configured for tightening the LH and RH screws, respectively, of the component assembled Station 13;
o. an electrical and visual inspection (Station 18) configured for visual and electrical inspection of the LMD unit assembled at Station 16.
p. a laser marking unit (Station 19) configured for laser marking of the unit assembled at Station 18; and
q. is an Ok NG Pick & Place Unit (Station 20) which shorts the OK component form NG component;
wherein, during the assembly the LMD is rotated by the assembly wheel (100) through all the stations in a continuous manner.

2. The automated machine as claimed in Claim 1, wherein the machine is operated and controlled through an Electric Panel (200).

3. The automated machine as claimed in Claim 2, wherein, the Electric Panel (200) is configured to synchronise the machine, such that each step on each station is done simultaneously

4. The automated machine as claimed in Claim 1, wherein the A Back Cover Placing unit (Station 01) is further provided with a hopper and chute assembly (12-13) for receiving back covers (201).

5. The automated machine as claimed in Claim 3, wherein the back covers (201) are placed on the assembly wheel (100) by a pick and place unit (401).

6. The automated machine as claimed in Claim 1, wherein, the Pin Bridge, Heater & PCB Placing Unit (Station 02) is provided with a chain type slat conveyer (501).

7. The automated machine as claimed in Claim 5, wherein the slat conveyer (501) is designed to carry the Pin Bridge, the Heater and the PCB assembly (500) to the Pin Bridge, Heater & PCB Placing Unit (Station 02).

8. The automated machine as claimed in Claim 6, wherein the placing of the Pin Bridge, the Heater and the PCB on slat conveyer (501) is done manually.

9. The automated machine as claimed in Claim 1, wherein, at the Refill holder Placing Station (Station 06), the refill holder is placed on the back assembly by a robotic arm (1002).

10. The automated machine as claimed in Claim 1, wherein, at the PCB Relocation Unit (Station 05 and 08), the PCB is relocated by a robotic arm (82).

11. The automated machine as claimed in Claim 1, wherein the Top Cover Placing Unit (Station 13) is provided with a hopper assembly (1501) for holding top covers.

12. The automated machine as claimed in Claim 1, wherein the Station 18 is configured for:
a. checking the supply of current through pin bridge (206) through electrical probe.
b. checking the actuation of switch knob (204) by pneumatic cylinder.
c. visually checking the working of led light (205);

13. The automated machine as claimed in Claim 10, wherein the top covers as placed over the sub-assembly by a robotic arm (1504).