Angular Precision Workplate for Hand Tool Guide Rails
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Solution Overview
Problem
Commercially available systems for processing sheet-like materials, especially in small workshops, suffer from low stiffness and precision, leading to inaccuracies in tool and workpiece positioning, which limits achievable angle accuracy and repeat accuracy due to small dimensioned components and limited locking positions.
Innovation Solution
A device featuring a work plate with strategically arranged holes for mounting positioning devices, allowing for precise and reproducible angle settings between the workpiece and guide rail, utilizing positioning devices of varying diameters and shapes to achieve high angular accuracy with minimal design effort, and enabling flexible machining of sheet materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If small dimensioned components are used in mobile/small workshop equipment, then the device size and weight are reduced, but manufacturing precision and stiffness deteriorate leading to angle accuracy losses
Solution Approach 1:
The device is segmented into distinct functional components: a work plate with precisely positioned holes, positioning devices that can be relocated, a guide rail, and a tool. The work plate serves as a rigid reference base with holes arranged at precise positions and angles, while the positioning devices can be moved to different holes to change the setup. This segmentation allows the critical reference elements (holes in work plate) to be manufactured with high precision independently, while the overall device remains compact and mobile.
2Device complexity
If few locking positions are provided (e.g., only 22.5-45-67.5 and 90 degrees), then the device complexity is reduced, but adaptability for intermediate angles deteriorates
Solution Approach 1:
The positioning devices are designed to be relocatable between multiple holes in the work plate, transforming the system from static fixed positions to a dynamic configuration. The holes are arranged at precise positions and angles, allowing the positioning devices to be moved to different combinations of holes to achieve various intermediate angles. This dynamic repositioning capability provides continuous angle adjustment flexibility without requiring complex mechanical adjustment mechanisms.
3Adaptability or versatility
If manual dialing in of angles is required, then adaptability for intermediate angles is improved, but measurement precision deteriorates due to small scale reading errors
Solution Approach 1:
The system replaces manual angular measurement and adjustment mechanisms (protractors, scales, dials) with a purely geometric positioning system. The desired angles are established by the physical arrangement of holes in the work plate and the positioning of devices in those holes, eliminating the need for reading scales or dials. The angle is determined by the fixed geometric relationship between hole positions rather than by operator interpretation of measurement instruments, thereby eliminating reading errors.
4Ease of operation
If a guide rail is placed manually on the workpiece, then ease of operation is improved, but manufacturing precision deteriorates due to freehand positioning inaccuracies
Solution Approach 1:
The work plate with precisely positioned holes acts as an intermediary between the operator and the guide rail positioning. Instead of placing the guide rail directly and manually aligning it with the workpiece, the operator positions positioning devices in the holes of the work plate, which in turn establish precise reference positions for the guide rail. This intermediary reference system eliminates the need for manual alignment while maintaining operational simplicity.
Data Source
AI summary
Disclosed is a device for angularly precise machining of a workpiece (9) by a tool (3) guided on a guide rail (2), wherein the tool may be, in particular, an electrically-operated hand tool such as a router or circular saw, etc., consisting of a one- or two-piece working panel (1), wherein the working panel (1) of the device is provided with a plurality of receptacles (4), which are arranged in suitable relation to each other and which serve to receive positioning devices (8) without play and perpendicularly to the working panel (1) such that, on one side, a workpiece (9) and, on the other side, a guide rail (2) for guiding a tool (3) can be positioned on or fixed to the working panel such that a defined and reproducible machining angle (11) forms between the face of the workpiece (9) to be processed, which rests against the positioning devices (8), and the guide rail (2), which is placed upon the workpiece (9) to be machined in order to guide the tool (3), which machining angle can be varied by re-inserting at least one of the positioning devices (8) into one of the receptacles (4) and/or by using positioning devices (8) of differently sized cross-sections, wherein the cross-section may be circular or even non-circular, wherein intermediate angles or “crooked” angular value can also be repeatedly set for machining by positioning devices (8), which are rotatable, non-circular in shape or eccentrically mounted, and may be fixed in their rotation.