Conical Disc-Spring Positioning for Repeatable XY Alignment
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Solution Overview
Problem
Accurate and repeatable positioning of objects in manufacturing environments is challenging due to factors like temperature stability, freedom of play, and elastic deformation, especially in automated and digitalized production where tolerances below 1 μm are difficult to maintain.
Innovation Solution
A positioning device featuring a disc spring with a tapered conical inner surface and a corresponding element with a tapered conical outer surface, allowing for precise alignment in X- and Y-directions by direct or indirect support, creating a reproducible zero point for fixtures, tools, and workpieces, suitable for both automated and manual production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional positioning methods (micrometer calipers, sliding calipers) are used, then manual positioning can be achieved, but positioning accuracy and repeatability depend on worker skill and machine stability rather than inherent system precision
Solution Approach 1:
The patent replaces manual measurement tools (micrometer calipers, sliding calipers) with a mechanical positioning system based on conical reference surfaces. The conical inner surface of the disc spring and conical outer surface of the positioning element create a self-aligning mechanism that eliminates dependency on operator skill, providing repeatable positioning through pure mechanical geometry rather than manual measurement.
Solution Approach 2:
The patent changes the positioning parameter from manual measurement values to a fixed geometric relationship defined by the conical surfaces. The taper angle and cone geometry establish a deterministic positioning parameter that is independent of human operation, transforming the positioning process from skill-dependent measurement to geometry-dependent mechanical alignment.
2Manufacturing precision
If high tolerances (below 1 μm) are required for accurate positioning, then positioning precision is improved, but maintaining these tolerances in real production environments is difficult due to temperature changes, pollution, and wear
Solution Approach 1:
The patent employs the disc spring as a cushioning element that compensates for environmental variations before they affect positioning accuracy. The spring's elastic properties absorb temperature-induced expansions, pollution-related debris, and wear variations, maintaining positioning tolerance below 1 μm despite harsh production conditions. The conical surfaces work with the spring to provide a forgiving interface that resists environmental degradation.
Solution Approach 2:
The positioning system combines the disc spring (elastic material) with conical reference surfaces (precise geometric elements) to create a composite positioning mechanism. This composite structure integrates the compliance needed to handle environmental variations with the geometric precision needed for sub-micron tolerances, achieving both high precision and reliability in production environments.
3Adaptability or versatility
If detachable positioning systems are used, then flexibility and adaptability are improved, but repeatability and accuracy are typically compromised
Solution Approach 1:
The patent segments the positioning system into detachable components (disc spring with conical inner surface, positioning element with conical outer surface, spacing devices) that can be assembled and disassembled while maintaining precision. The modular design allows different objects to be positioned detachably through the standardized conical interface, ensuring repeatability across multiple assembly cycles without compromising accuracy.
Solution Approach 2:
The conical reference surface interface serves as a universal positioning mechanism that works across multiple detachable connections between different objects (fixtures, tools, workpieces, pallets). This universal interface ensures that the same high level of repeatability and accuracy is achieved regardless of which objects are being positioned, enabling the detachable system to maintain manufacturing precision while providing flexibility.
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
Enables precise and reproducible positioning with high accuracy, suitable for digitalized production and assembly of components like cylinder heads and engine blocks, even in tough environmental conditions, with high endurance and cost-effectiveness.
Implementation Method 1
a first XY-reference means (8) and a second corresponding XY-reference means (10), wherein the first XY-reference means (8) is a disc spring with a in Z-direction tapered conical inner surface (12) and the second XY-reference means (10) is an element with an in Z-direction tapered conical outer surface (14)
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The invention relates to a positioning device (2) for detachable and repeatable positioning in X-, Y- and Z-directions of a first object (4) in relation to a second object (6), the positioning device (2) comprising a first XY-reference means (8) and a second corresponding XY-reference means (10), wherein the first XY-reference means (8) is a disc spring with a in Z-direction tapered conical inner surface (12) and the second XY-reference means (10) is a element with an in Z-direction tapered conical outer surface (14), where further the first XY-reference means (8) is arranged to be fixed to the first object (4) and the second XY-reference means (10) is arranged to be fixed to the second object (6), where in operating state of the device the first object (4) is positioned in the Z-direction in relation to the second object (6) by that the second object (6) is arranged to support the first object (4) in the Z-direction, and where at the same time the conical outer surface (14) of the second XY- reference means (10) is arranged to abut against the conical inner surface (12) of the first XY- reference means (8) thus in turn positioning the first object (4) in relation to the second object (6) in X- and Y-direction.