Complex Surface Fixture Alignment With Elastic Averaging
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Solution Overview
Problem
Current manufacturing and service fixture tooling requires long lead times and high costs, especially for low volume production runs and in-field service/repair purposes, while maintaining accurate and repeatable alignment of components with complex locating features is challenging due to the need for dedicated locating features and clearance for tolerance variations.
Innovation Solution
The use of additive manufactured fixtures with complex, smoothly contoured surfaces and elastically deformable structures that provide an elastic averaging effect, combined with integrated magnets and sensors, allows for precise component alignment without referencing a fixed datum point, enabling efficient and accurate positioning of components using complex algebraic surfaces and compliance-tailored features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used to create dedicated locating features, then locating precision can be maintained, but production time and cost increase significantly
Solution Approach 1:
The patent changes the manufacturing method from traditional subtractive or formative processes to additive manufacturing, enabling complex locating features to be produced directly from digital models. This parameter change in manufacturing approach reduces lead time while maintaining precision through digital control of the additive process
Solution Approach 2:
The patent uses math data (digital models) to directly generate the locating features through additive manufacturing, creating a digital copy that is directly transformed into the physical feature without requiring separate tooling or dedicated locating features, thus reducing production time
2Adaptability or versatility
If clearance is designed into locating features to account for tolerance variations, then adaptability to tolerance variations is improved, but locating precision decreases
Solution Approach 1:
The patent introduces compliant locating features that are elastically deformable, allowing the locating structure to dynamically adapt to tolerance variations in the workpiece. The elastic deformation enables the fixture to accommodate dimensional variations while maintaining precise locating through the elastic recovery force
Solution Approach 2:
The patent changes the stiffness parameter of the locating features by using compliant, elastically deformable structures instead of rigid features. This parameter change allows the locating system to accommodate tolerance variations while maintaining precision through the elastic properties of the material
3Manufacturing precision
If complex locating features are created using traditional methods, then locating accuracy is maintained, but device complexity and cost increase
Solution Approach 1:
The patent creates locating features that serve multiple functions: they provide precise locating, accommodate tolerance variations through elastic deformation, and are manufactured efficiently through additive processes. The same complex geometry that provides locating accuracy also provides the compliance needed for tolerance accommodation
Solution Approach 2:
The patent uses math data to directly generate complex locating features through additive manufacturing, eliminating the need for separate tooling or assembly steps. The digital model directly defines the complex geometry that provides both locating accuracy and compliance, reducing device complexity
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 reduces production time and cost, provides high precision in component alignment, and facilitates the use of fixtures in low volume builds and field repairs by overconstraining components with elastic averaging features, while embedding magnets and sensors for improved joining quality.
Implementation Method 1
at least one of the locators embodies an elastically deformable structure and provides an elastic averaging effect in locating the fixture relative to at least one of the components
Implementation Method 2
The fixture includes an integrated magnet that holds the fixture to at least one of the components
Data Source
AI summary
Systems and methods are provided for locating a pair of components relative to one another using complex surfaces. One component has a complex surface, where the complex surface is smoothly contoured. Another component is shaped to be connected with the first component. A fixture locates the first component relative to the second component. The fixture includes a locator with a complex surface region shaped to mate with the complex surface of the one component to locate the fixture relative to that component. The fixture includes another locator to locate the fixture relative to the second component.