Adaptive Tool Base Assembly for Reconfigurable Base Plate Tooling
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Solution Overview
Problem
Current tooling solutions require replacement of entire base plates and tooling components for design changes, leading to increased costs and inefficiencies when manufacturing different products.
Innovation Solution
An adaptive tooling system featuring a base plate assembly with matrix holes and location pins, allowing for interchangeable tool base assemblies that can be reconfigured to accommodate various product shapes and sizes without replacing the entire system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed tooling components are used on a base plate, then the tooling provides stable support for manufacturing, but the entire base plate and tooling components must be replaced when product design changes occur
Solution Approach 1:
The tooling system is divided into modular components: a base plate with matrix holes, removable location pins, and interchangeable tool base assemblies. This segmentation allows individual components to be replaced or reconfigured without replacing the entire tooling system, resolving the contradiction between stability and adaptability.
Solution Approach 2:
The tooling system transitions from a static fixed configuration to a dynamic reconfigurable system. Location pins can be removed and repositioned in different matrix holes, and tool base assemblies can be interchangeably mounted, enabling the tooling to adapt to different product designs while maintaining operational stability during use.
2Adaptability or versatility
If new tooling components are manufactured for each product change, then the tooling accommodates new product designs, but the manufacturing cost increases significantly
Solution Approach 1:
The base plate with its matrix of holes serves multiple functions: it provides a stable mounting surface, enables repositioning of tooling components, and supports different product configurations. This universal base plate replaces the need to manufacture new base plates for each product change, reducing material consumption while maintaining design flexibility.
Solution Approach 2:
Instead of discarding entire tooling systems when product designs change, only specific tool base assemblies are replaced or repositioned. The base plate and location pins are recovered and reused, significantly reducing the quantity of material consumed compared to manufacturing entirely new tooling components.
3Adaptability or versatility
If the entire base plate is replaced for design changes, then the tooling accommodates new products, but the time and resources required for replacement increase
Solution Approach 1:
The tooling system is segmented into a permanent base plate and removable tool base assemblies. When product design changes occur, only the tool base assemblies need to be removed and repositioned, not the entire base plate. This segmentation dramatically reduces the time and resources required for tooling changes.
Solution Approach 2:
The base plate is pre-configured with a matrix of holes in specific patterns that anticipate future reconfiguration needs. Location pins are pre-positioned in these holes to establish accurate tooling locations. This preliminary preparation enables rapid reconfiguration when product designs change, minimizing the time required for tooling changes.
Data Source
AI summary
An example adaptive tooling system is provided that includes an adaptive base plate assembly and a tool base assembly selectively engageable with each other. The adaptive base plate assembly includes a base plate with holes formed therein, and location pins attached to the base plate via the holes. The tool base assembly includes a central support member, first and second lock plates, and a latch pivotably disposed relative to the central support member. The first and second lock plates include an opening formed therein. The opening of the lock plates is configured to at least partially receive first and second location pins of the location pins of the adaptive base plate assembly. The latch is configured to releasably engage with a third location pin of the location pins of the adaptive base plate assembly to releasably engage the tool base assembly with the adaptive base plate assembly.