Adaptive Magnetic Fixturing for RV Frame Alignment Without Master Frames
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Solution Overview
Problem
The recreational vehicle (RV) industry faces challenges with the large size and weight of metal frames used in sidewalls, floors, and ceilings, which require significant storage space and can warp over time, necessitating a more efficient manufacturing method that eliminates the need for master frames and stack welding.
Innovation Solution
An adaptive fixturing system that includes a work surface and tool fixtures with a coupler for securing components, a computer for controlling the placement of tool fixtures based on component location data, and a storage system for tool fixtures when not in use, allowing for alignment and processing of components without the need for master frames, using magnetic, pneumatic, or frictional couplers for securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stack welding with master frames is used, then welding capability is provided, but storage space requirements increase significantly
Solution Approach 1:
The patent replaces physical master frames with a digital copy (computer-controlled system) that stores frame geometry data. This digital replica eliminates the need for physical master frames while maintaining the ability to reproduce exact frame configurations, directly resolving the storage space contradiction.
Solution Approach 2:
The invention extracts the essential function of master frames (providing geometry and alignment) and separates it from the physical frame structure itself. By using independent positioning devices and digital data storage, the system removes the storage burden while preserving the alignment and positioning capabilities.
2Area of stationary object
If master frames are stored stacked, then storage efficiency is improved, but frame warping occurs over time
Solution Approach 1:
By using digital copies of frame geometry stored in a computer rather than physical master frames, the system eliminates the warping problem entirely. The digital data remains stable and does not deform, while still providing the necessary geometric reference for frame construction.
Solution Approach 2:
The patent replaces the mechanical master frame system with a computer-controlled positioning system. This substitution eliminates the physical storage and handling of master frames, thereby preventing warping while maintaining positioning accuracy through digital control.
3Ease of manufacture
If large master frames are used, then frame construction capability is provided, but handling becomes unwieldy
Solution Approach 1:
The system divides the master frame functionality into separate, manageable components: digital data storage, computer control, and individual positioning devices. This segmentation allows each component to be small and easy to handle while collectively providing the full frame construction capability.
Solution Approach 2:
The patent replaces the large, unwieldy mechanical master frames with a computer-controlled system that uses digital data and small positioning devices. This substitution maintains frame construction capability while eliminating the handling difficulties associated with large physical master frames.
4Adaptability or versatility
If multiple master frames are maintained for different RV models, then manufacturing versatility is improved, but storage requirements increase
Solution Approach 1:
The computer-controlled system serves as a universal platform that can store and process geometry data for multiple different RV models and frame configurations. This single multi-functional system replaces the need for multiple specialized master frames, thereby reducing storage requirements while maintaining manufacturing versatility.
Solution Approach 2:
The system creates digital copies of various frame designs and configurations in the computer's memory. These digital replicas allow the system to adapt to different RV models without requiring physical master frames for each model, achieving versatility with minimal storage space.
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
The system reduces storage needs, minimizes handling issues, and prevents frame warping by allowing precise alignment and processing of RV components, such as welding, gluing, or molding, while enabling efficient reuse of tool fixtures and monitoring for wear or damage.
Implementation Method 1
when the coupler comprises a magnet, the magnet is mounted to the carrier
Implementation Method 2
the coupler may comprise a pneumatic coupler, such as a suction cup, with the computer controlling the flow of air to and from the pneumatic coupler
Implementation Method 3
the retaining surface may be configured to simply frictionally engage the component on the work surface
Data Source
AI summary
A fixturing system for processing components includes a work surface, such as a table formed from a ferromagnetic material, a tool fixture having a magnet operable for securing the tool fixture to the work surface and having at least one alignment surface to hold and/or align a component to the tool fixture and to the work surface. The system further includes a storage location spaced from the work surface for storing the tool fixture when not in use on the work surface, a work piece, and optionally a robotic arm with a controller to move the work piece and robotic arm, and a computer having stored therein component location data. The computer is configured to control the work piece to retrieve the tool fixture from the storage location and to place the tool fixture on the work surface at a tool fixture location based on the component location data for aligning, and optionally holding the two components with the tool fixture while being processed.