Alignment Spacer Assembly for Precise Welding of Large Components
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Solution Overview
Problem
Traditional manufacturing methods require expensive downstream machining after welding larger components, which is difficult with larger machinery.
Innovation Solution
An alignment spacer assembly comprising spacer segments and a securing device, such as a securement pin or clamp, that positions components at a fixed distance during welding, allowing for precise alignment and subsequent removal without the need for extensive post-weld machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding followed by downstream machining is used for larger components, then manufacturing precision can be achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The alignment spacer assembly performs the alignment function before welding occurs. The spacers are pre-positioned between components with precise dimensional tolerances, establishing accurate component spacing and orientation prior to the welding process. This preliminary alignment action eliminates the need for complex post-weld machining operations.
Solution Approach 2:
The alignment spacer assembly acts as an intermediary device between components during welding. It provides a physical medium that maintains precise spacing and alignment between welded components, transferring alignment precision without requiring complex machining equipment. The spacers serve as temporary mediators that are removed after welding completes.
2Manufacturing precision
If downstream machining is performed after welding larger components, then manufacturing precision is achieved, but loss of time increases due to additional processing steps
Solution Approach 1:
Alignment is performed as a preliminary action before welding rather than as a subsequent machining operation. The alignment spacer assembly is installed prior to welding, establishing precise component positioning in advance. This resequencing of operations eliminates the need for time-consuming post-weld machining and reduces total manufacturing cycle time.
Solution Approach 2:
The alignment and welding operations are merged into a single integrated process. By using alignment spacers that remain in place during welding, the patent combines what would traditionally be separate operations (alignment followed by welding followed by machining) into a more efficient sequence where alignment and welding occur concurrently with the spacers in place.
3Device complexity
If traditional welding without alignment spacers is used, then device complexity is reduced, but manufacturing precision deteriorates due to lack of precise spacing control
Solution Approach 1:
The alignment spacer assembly serves as a simple intermediary device that provides precise spacing control without adding significant complexity to the welding setup. The spacers are basic mechanical components with fixed dimensions that physically maintain accurate spacing between components during welding, achieving manufacturing precision through a straightforward mechanical solution rather than complex control systems.
Solution Approach 2:
The patent changes the physical parameter of spacing control from a process-controlled parameter to a geometry-defined parameter. Instead of relying on complex positioning systems or process control, the alignment spacers encode precise spacing dimensions directly into their physical geometry. This parameter change simplifies the welding setup while maintaining high manufacturing precision through the spacers' fixed dimensional characteristics.
Data Source
AI summary
A spacer assembly and method for using same to fix a first component to a second component are provided. The method includes positioning the first and second spacer segments between the first and second components, the first and second spacer segments each including an inner face, an opposite outer face, and an exterior surface extending along a longitudinal axis between the inner face and the outer face. The exterior surfaces of the first and second spacer segments are coaxially aligned and secured by a securing device such that the inner faces of the first and second spacer segments define supplementary non-perpendicular angles relative to the longitudinal axis and the outer faces of the first and second spacer segments are parallel to one another. The securing device and the first and second spacer segments are removed after the first component is mechanically coupled to the second component.