Alignment Spacer Segments for Fixed-Gap Welding of Large Components

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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

The use of alignment spacer assemblies comprising spacer segments with angled inner and outer faces and alignment bores, secured by a securement pin or clamp, to position components at a fixed distance for welding, allowing for precise alignment and coupling without the need for extensive machinery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional welding and machining methods are used for larger components, then manufacturing precision can be achieved through downstream machining, but device complexity and equipment costs increase significantly

Engineering Contradiction:

Improvealignment precisionVSAvoidequipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The alignment spacer assembly performs preliminary positioning and alignment of components before welding. The spacers are pre-positioned between components to establish precise spacing and alignment, allowing welding to proceed without requiring complex positioning equipment. This preliminary action eliminates the need for expensive downstream machining operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The alignment spacer assembly acts as an intermediary device between components during welding. The spacers serve as mediators that maintain fixed distances and alignment between components, enabling precise positioning without requiring complex external positioning equipment or machinery.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If traditional welding methods are used for larger components, then components can be welded together, but handling and positioning difficulty increases

Engineering Contradiction:

Improveease of handlingVSAvoidpositioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The alignment spacer assembly is self-contained and self-positioning. The spacers have features like holes and surfaces that allow them to be easily positioned and secured between components without requiring external positioning equipment. The assembly serves itself to maintain alignment and spacing, making handling of large components simple while ensuring positioning accuracy.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If downstream machining is performed after welding, then manufacturing precision can be achieved, but loss of time and increased manufacturing cost occur

Engineering Contradiction:

Improvedimensional accuracyVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The alignment spacers perform preliminary positioning and alignment before welding, establishing precise dimensional relationships between components. By pre-establishing accurate spacing and alignment during assembly, the need for time-consuming downstream machining operations is eliminated, reducing overall manufacturing cycle time while maintaining dimensional accuracy.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If expensive tooling and equipment are used for welding and machining, then manufacturing precision can be maintained, but manufacturing cost increases

Engineering Contradiction:

Improvealignment accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The alignment spacer assembly represents a simple, inexpensive positioning device that can be easily manufactured and discarded or reused. Instead of investing in expensive precision positioning equipment or tooling, the patent uses simple spacer components with basic geometric features that provide accurate alignment at minimal cost. These spacers can be made from inexpensive materials and do not require complex mechanisms.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS12109654B2Alignment spacer assemblies for welding and methods for using same

Publication Date: 2024.10.08 CROWN EQUIP CORP

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.