Alignment Spacer Assembly for Precise Welding of Large Components
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Solution Overview
Problem
Traditional manufacturing methods require expensive tooling and equipment for welding and subsequent machining of components, which becomes impractical for larger components due to the difficulty in handling and positioning them accurately during welding operations.
Innovation Solution
An alignment spacer assembly comprising spacer segments with angled inner and outer faces and a securing device, such as a securement pin or V-block clamp, that positions components at a fixed distance for welding, allowing for precise alignment and mechanical coupling without the need for extensive downstream machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding and subsequent machining methods are used, then manufacturing precision can be achieved, but device complexity and cost increase due to expensive tooling and equipment
Solution Approach 1:
The alignment spacer assembly performs the alignment function before welding, allowing components to be positioned precisely during the welding operation itself. The spacers are pre-positioned between components to establish accurate spacing and alignment, eliminating the need for subsequent machining operations and reducing overall device complexity
Solution Approach 2:
The alignment spacer assembly acts as an intermediary device between components during welding. It provides a simple mechanical structure with angled faces that facilitate precise positioning and maintain accurate component spacing throughout the welding process, replacing complex tooling and positioning equipment
2Manufacturing precision
If components are welded and then machined downstream, then manufacturing precision is maintained, but productivity decreases due to additional processing steps
Solution Approach 1:
The alignment spacers are positioned in advance during the welding operation, establishing precise component alignment before welding begins. This preliminary positioning action eliminates the need for subsequent machining steps, reducing manufacturing cycle time while maintaining precision
Solution Approach 2:
The invention merges the alignment and welding operations into a single process step. By using alignment spacers that maintain precise component spacing during welding, the need for separate downstream machining operations is eliminated, combining multiple process steps into one efficient operation
3Ease of manufacture
If larger components are welded using traditional methods, then welding can be performed, but ease of operation deteriorates due to difficulty in handling and positioning
Solution Approach 1:
The alignment spacer assembly is divided into multiple segments that can be individually positioned and assembled between larger components. This segmentation makes the alignment device itself easier to handle and position, even when working with large components that would be difficult to maneuver
Solution Approach 2:
The alignment spacer assembly serves as an intermediary tool that simplifies the handling and positioning of larger components during welding. By providing a simple mechanical interface with angled faces, it enables easy positioning and alignment without requiring complex handling equipment or procedures
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.