Additive Guide Features for Tubular Member Assembly Accuracy
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Solution Overview
Problem
Traditional manufacturing aides require secondary processing steps that increase time, effort, and 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 tubular member, allowing for partial insertion and preventing further penetration, with a braze material guided by capillary action and an assembly aid providing an interference fit or keyway, while allowing insertion direction indicia.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional secondary processing methods are used for assembly assistance, then assembly guidance can be provided, but assembly time increases and errors are introduced
Solution Approach 1:
The patent combines the assembly guidance function directly into the tubular member by additively manufacturing raised features (such as ribs or protrusions) as integral parts of the member itself, rather than using separate secondary processing methods. This merging eliminates the need for additional assembly steps while providing built-in alignment and insertion guidance, thereby reducing assembly time without sacrificing accuracy
Solution Approach 2:
The raised assembly assistance features are manufactured in advance as part of the tubular member through additive manufacturing. These features are pre-formed to provide alignment and guidance functions before the actual assembly operation begins, eliminating the need for time-consuming secondary processing during assembly while ensuring accurate positioning
2Reliability
If traditional secondary processing methods are used for assembly assistance, then assembly guidance can be provided, but device complexity increases
Solution Approach 1:
The patent integrates the assembly assistance function directly into the tubular member design by additively manufacturing raised features as integral components. This eliminates the need for separate secondary processing equipment, fixtures, or additional manufacturing steps, thereby reducing process complexity while maintaining assembly accuracy through built-in alignment and guidance features
3Productivity
If additive manufacturing is used to deposit guide material, then assembly is simplified and time is reduced, but material deposition complexity increases
Solution Approach 1:
The patent uses directed energy deposition with controlled parameters to melt and fuse material onto the tubular member surface, creating raised assembly assistance features. By optimizing deposition parameters such as energy input, deposition rate, and layer thickness, the process achieves efficient material placement that simplifies assembly while managing the complexity of the deposition process through precise parameter control
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, reduces time, and improves fit quality by minimizing deformation and avoiding unnecessary processing steps, resulting in reduced size, weight, complexity, and cost, while maintaining assembly accuracy.
Implementation Method 1
The depositing the first material on the first member by an additive manufacturing process can be done by directed energy deposition
Implementation Method 2
The braze material can be guided by the first the material by capillary action
Data Source
AI summary
A method including depositing a first material on a first member by an additive manufacturing process in a pattern intended to aid in an assembly of the first member and at least a second member and inserting the first member at least partially into the second member, with the first material being guide for insertion.