Accumulator Piston Alignment Fixture with Laser Guidance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The installation and removal of large pistons in cylinder assemblies, such as those used in accumulators, often result in costly damage due to misalignment, requiring multiple personnel and lacking precise alignment mechanisms.
Innovation Solution
An accumulator assembly fixture with a frame, vee blocks, a laser alignment system, alignment screws, a piston support carriage driven by a drive train, and a push rod for precise alignment and insertion/removal of pistons while minimizing personnel and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple personnel are used to manually align and install the piston, then the alignment process can be performed, but the risk of misalignment and damage increases due to human error
Solution Approach 1:
The patent replaces manual mechanical alignment methods with a laser alignment system that uses optical beams and detectors to precisely align the piston with the cylinder axis. The laser alignment system provides objective, measurable alignment data without human error, directly resolving the contradiction between achieving precision alignment and preventing damage from misalignment.
Solution Approach 2:
The patent introduces alignment fixtures and guide mechanisms as intermediary devices between the piston and cylinder. These fixtures include alignment pins, guide rails, and positioning devices that physically constrain the piston to follow the correct alignment path, preventing misalignment damage while reducing reliance on multiple personnel for manual alignment.
2Ease of operation
If manual alignment procedures are used, then installation can be performed, but the number of personnel required increases and productivity decreases
Solution Approach 1:
The patent implements self-aligning features on the piston and cylinder assembly, such as keyed alignment surfaces, tapered guides, and automatic positioning mechanisms. These features enable the components to align themselves during installation without requiring multiple personnel to manually position and adjust each component, thereby simplifying the operation while improving productivity.
Solution Approach 2:
The patent incorporates pre-aligned fixture assemblies and pre-positioned alignment features that are prepared before the actual piston installation. The alignment fixtures are pre-calibrated and positioned to guide the piston along the correct path, eliminating the need for multiple personnel to perform complex alignment procedures during installation, thus improving both ease of operation and productivity.
3Reliability
If traditional alignment methods are used, then the installation process can proceed, but manufacturing precision and alignment accuracy are insufficient
Solution Approach 1:
The patent replaces traditional mechanical alignment methods (such as visual estimation, manual measuring tools, and trial-and-fit procedures) with a laser-based optical alignment system. The laser system projects reference beams and uses detectors to measure deviations from the ideal alignment path with high precision, enabling accurate alignment that exceeds the capabilities of manual mechanical methods.
Solution Approach 2:
The patent introduces optical measurement dimensions by using laser beams that can detect alignment deviations in multiple spatial dimensions simultaneously. The laser alignment system measures positional deviations in X, Y, and Z directions, providing comprehensive three-dimensional alignment data that enhances manufacturing precision beyond what traditional single-dimensional mechanical alignment methods can achieve.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures proper axial alignment of pistons within cylinders during installation and removal, reducing the risk of damage and the number of personnel required, thereby enhancing operational efficiency and reducing costs.
Implementation Method 1
a laser alignment system comprising a laser and a laser alignment block having a laser alignment sight
Data Source
AI summary
A device that helps to properly align and install large pistons in cylinders is disclosed. Large pistons and cylinders are heavy and difficult to handle, and if the piston is not inserted in the cylinder perfectly in line with the length of the cylinder, damage results. The device holds both the piston and cylinder being assembled, and has a number of alignment mechanisms. A laser is also used to set up the device and to ensure that the piston is straight with the center line of the cylinder for proper alignment and insertion.