Additive Assembly Guides for Precise Member Insertion
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Solution Overview
Problem
Traditional manufacturing aides require secondary processing steps that increase time and effort, and can introduce errors, necessitating improved adaptability and economic viability in assembly methods.
Innovation Solution
The method involves using additive manufacturing to deposit a guide material on a first member, which aids in the assembly of a second member, allowing for partial insertion and preventing over-insertion, with features like capillary action for braze material and microstructural deformation without melting, and including indicia for direction, to facilitate efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional secondary processing methods are used to aid assembly, then assembly guidance can be provided, but assembly time and complexity increase
Solution Approach 1:
The patent combines the assembly aid feature directly with the base component by additively manufacturing the guide feature as an integrated part of the component itself, eliminating the need for separate secondary processing steps or additional assembly aids. This merging of functions reduces assembly time while maintaining ease of operation.
Solution Approach 2:
The guide feature is additively manufactured onto the component surface before final assembly, preparing the component in advance with built-in alignment and positioning capabilities. This preliminary action eliminates the need for time-consuming secondary processing during the assembly operation.
2Ease of operation
If traditional secondary processing methods are used to aid assembly, then assembly guidance can be provided, but the number of processing steps increases
Solution Approach 1:
The patent merges the assembly guidance function into the base component design, where the guide feature is additively manufactured as an integral part of the component. This eliminates the need for separate secondary processing equipment and steps, reducing overall process complexity while maintaining ease of operation.
Solution Approach 2:
The additive manufacturing process enables the base component to serve multiple functions: it provides the primary structural function while simultaneously incorporating assembly guidance features. This multi-functionality reduces the need for additional dedicated assembly aids and processing steps.
3Ease of operation
If traditional secondary processing methods are used to aid assembly, then assembly guidance can be provided, but error introduction increases
Solution Approach 1:
By integrating the assembly guide feature directly into the base component through additive manufacturing, the patent eliminates interfaces between separate components that could introduce misalignment errors. The monolithic structure ensures precise relative positioning and reduces opportunities for human error during assembly.
Solution Approach 2:
The guide feature is created in advance as part of the base component manufacturing process, ensuring precise geometric relationships are established before assembly begins. This preliminary formation of accurate guidance features prevents errors that could occur during separate secondary processing operations.
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 approach simplifies assembly procedures, reduces time, improves fit quality, and decreases waste, while being economically viable by minimizing unnecessary processing steps and ensuring precise alignment.
Implementation Method 1
The braze material can be guided by the first the material by capillary action
Data Source
Figure 1
Figure 2~2a
Figure 3
AI summary
A method including depositing a first material on a first member (302, 402) by an additive manufacturing process in a pattern intended to aid in an assembly of the first member and at least a second member (304) and inserting the first member (302, 402) at least partially into the second member (304), with the first material being guide for insertion.