Adaptive Tooling Fixture for Automatic Workpiece Centerline Alignment
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Solution Overview
Problem
In manufacturing, workpieces often require precise positioning during machining to prevent vibration and machining errors, but existing methods, such as manual shimming, are labor-intensive and time-consuming, and may introduce preload errors.
Innovation Solution
A tooling fixture with linear actuators and vacuum grippers that automatically reposition a workpiece to align its centerline with an indexing position, eliminating the need for manual shimming by measuring offsets and applying vacuum to secure the workpiece in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual shimming is used to align the workpiece on the fixture, then the workpiece can be positioned, but the process is labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical shimming operations with an automated sensor-based measurement system and actuator-driven repositioning system. Sensors measure the workpiece position relative to the fixture indexing position, and actuators automatically adjust the workpiece location, eliminating manual labor and reducing setup time.
Solution Approach 2:
The fixture system performs self-alignment by automatically measuring its own workpiece positioning accuracy using integrated sensors and correcting misalignment through actuator-driven repositioning, without requiring external manual intervention.
2Manufacturing precision
If rigid holding is applied to prevent vibration during machining, then machining accuracy improves, but pre-load on the workpiece may be introduced causing errors
Solution Approach 1:
The patent employs dynamic, adjustable holding forces through vacuum grippers that can be selectively applied to different locations on the workpiece. The system adjusts the magnitude and distribution of holding forces based on real-time position measurements, providing sufficient rigidity to prevent vibration while avoiding excessive pre-load that could cause machining errors.
Solution Approach 2:
The patent applies localized vacuum holding forces at specific contact points rather than uniform rigid constraints across the entire workpiece. This allows selective application of holding forces only where needed to prevent vibration, minimizing unwanted pre-load effects on critical machining surfaces.
3Productivity
If automated repositioning is implemented to eliminate manual shimming, then productivity improves, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single automated fixture system: sensors perform both measurement and alignment verification, actuators provide both repositioning and securing functions, and vacuum grippers provide both holding and positioning capabilities. This multi-functionality reduces the need for separate manual operations and tools.
Solution Approach 2:
The patent introduces sensors as intermediary devices that bridge the gap between manual positioning operations and automated control. The sensors provide real-time feedback on workpiece position, enabling the controller to make precise adjustments without requiring complex direct mechanical coupling between the workpiece and fixture.
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
This solution reduces setup time and labor, improves alignment accuracy, and prevents machining errors by semi-automatically positioning the workpiece, thereby enhancing the efficiency of machining operations.
Implementation Method 1
The controller applies a vacuum to the vacuum gripper to grip the surface of the workpiece
Data Source
AI summary
A fixture and a method of operating the fixture are disclosed for repositioning a workpiece disposed on the fixture to correct an offset between the centerline of the workpiece and an indexing position on the fixture. The fixture includes one or more linear actuators that linearly move vacuum grippers on their outboard ends into contact with surfaces of the workpiece. Vacuum is applied to the vacuum grippers, which enables the vacuum grippers to grip the surfaces of the workpiece. The linear actuators are driven to reposition the workpiece on the fixture to reduce the offset between the two below a threshold value. When in position, the fixture secures the workpiece in place for subsequent machining operations that may be performed on the workpiece.