Systems and methods for modular instrument design and fabrication

Abstract

Modular component mounting systems and methods employ a plurality of members adapted to be interlocked with one another and anchored to an instrument housing. Each of the members comprises a central elongated body, cross-holes extending transversely through the body, beads extending along corners of the body to a position spaced apart from an end of the body defining a key at the end of the body, a channel defined by a surface of the body and a pair of the beads to receive and register with a key of another member, and a fastener receptive orifice defined in the end of the body. A fastener extends though one of the cross-holes of a first member to be received by an end orifice of a second member, interlocking the members and preventing torsional movement by the members relative to one another.

Description

BACKGROUND OF THE INVENTION [0001] Many electronic systems, instruments, and the like must be custom designed and / or fabricated. Such instruments may include processor-based systems, communications equipment, networking equipment, switch matrixes, testing equipment, and the like. Such equipment may be developed to meet specific requirements of a customer and may be one of a kind or small production runs, such as of fifteen or fewer units. However, these same customers expect, or at least desire, an inexpensive solution to such custom applications, provided in a timely manner. [0002] Traditionally, even small run jobs are treated as truly custom jobs that involve custom designing each part including housing and mounting sheet metal, machined parts and the like. This is time consuming and costly. Not only is the cost of a small run of custom parts expensive, overhead related to these custom or small production runs is relatively high as the resulting instrument and its parts require m...

AI Technical Summary

Benefits of technology

[0005] Embodiments of systems and methods for modular instrument or system design and fabrication may employ a plurality of members adapted to be interlocked with one another and anchored to an instrument housing structure. Each of these integral members has a central elongated body portion, which might have a generally square cross section. Cross-holes may extend transversely through the central body portion, in at least one direction. Bead portions extend along, at least, a pair of corners of the body, to a point spaced apart from an end of the body portion this may result in a key portion of the body being formed at an end of the body. A channel portion is defined by a surface of the body and a pair of the beads, the channel is adapted to register with a key of another member. A fastener receptive threaded orifice is defined in the end of the body. This orifice may be defined by a central cannula extending through a length of the body. Embodiments of the present systems and methods also employ fasteners extending though a cross-hole of a first of the members to be received by an end orifice of a second of the members, interlocking the first and second members and preventing torsional movement by the members relative to one another.

Problems solved by technology

This is time consuming and costly.

Not only is the cost of a small run of custom parts expensive, overhead related to these custom or small production runs is relatively high as the resulting instrument and its parts require many of the overhead processes and procedures that a mass produced product requires.

Also, it takes time to fabricate custom parts and the time required to gather all of the custom produced parts may also present problems, particularly where multiple vendors are involved, as is often the case.

When prototyping, or at the beginning of fabrication, it is often found that a custom piece is missing or not made as specified.

At this time, it might be determined that a redesign of the instrument is necessary causing further delay and cost.

In such cases, it may be necessary to have one or more new pieces fabricated, causing a halt, or at least a delay, in the prototyping process or in product production.

Custom designed instruments often have undesirable qualities.

For example the final product may be a relatively “closed” system that requires tortuous cable routing and an inflexibility limiting the ability to make changes or enhancements to the instrument.

Custom produced instruments are often cluttered with long cable runs required or with cables routed through sheet metal decks or the like.

Additionally, design may be problematic in that the instrument designers may be designing an instrument that uses components that the designers do not have on-hand, and for which the designers may not know the actual, final dimensions or configuration.

However, such frames are typically configured for use in a single instrument design, are costly, and time consuming to fabricate.

Problematically, custom fabricated sheet metal or manual drilling of sheet metal elements must be used to mount PCBs for custom instrument fabrication.

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