Adaptive Tooling Fixture for Automatic Workpiece 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 fixtures rely on labor-intensive manual shimming processes, which are time-consuming and prone to inaccuracies.
Innovation Solution
A tooling fixture equipped with linear actuators and vacuum grippers that automatically reposition a workpiece to align its centerline with the fixture's 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
1Measurement precision
If manual shimming process is used to align workpiece, then alignment can be achieved, but setup time and labor are excessive
Solution Approach 1:
The patent replaces the manual mechanical shimming process with an automated system using linear actuators and sensors. The sensor measures the offset between workpiece centerline and indexing position, and the linear actuator automatically adjusts the workpiece position, eliminating manual labor and reducing setup time while maintaining alignment accuracy.
Solution Approach 2:
The fixture system performs self-alignment by using its own sensor to detect the offset and its own linear actuator to correct the position. The system autonomously measures and adjusts without external intervention, making the alignment process self-service and eliminating the need for manual shimming.
2Reliability
If workpiece is rigidly held in fixed position, then vibration and machining errors are reduced, but pre-load on workpiece may be introduced
Solution Approach 1:
The patent uses a dynamic positioning system where the linear actuator can adjust the workpiece position during machining operations. This allows the fixture to maintain optimal contact and stability while accommodating workpiece deflection and thermal expansion, preventing pre-load accumulation that would occur with completely rigid fixed positioning.
Solution Approach 2:
The system changes the positioning parameters dynamically by using sensor feedback to monitor and adjust the workpiece position. The linear actuator modifies the contact force and position based on real-time measurements, maintaining stability without introducing harmful pre-load conditions.
3Ease of operation
If manual alignment process is used, then workpiece can be positioned, but labor intensity is high
Solution Approach 1:
The patent replaces manual positioning operations with an automated sensor-actuator system. The sensor automatically measures the offset and the linear actuator automatically positions the workpiece, eliminating manual labor while maintaining full positioning capability.
Solution Approach 2:
The system incorporates sensor feedback to automatically monitor and adjust workpiece position. The sensor measures the offset between workpiece centerline and indexing position, and this feedback information is used by the linear actuator to make precise positioning adjustments without manual intervention.
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, 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.