Universal Testing Machine Crosshead Asymmetric Aperture Design
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Solution Overview
Problem
The existing universal testing machine crossheads are heavy, expensive, and require costly special casting for offset column locations, leading to high upfront fees and material costs.
Innovation Solution
A rectangular crosshead design with a wedge pocket machined at an angle to the front surface, allowing the use of steel plate stock instead of casting, reducing material costs and eliminating the need for special pattern charges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If crossheads are designed with offset cast portions for column apertures, then the universal testing machine can accommodate column locations, but the crosshead becomes very heavy and expensive requiring special casting
Solution Approach 1:
The crosshead design uses asymmetric column aperture locations that are not centered on the crosshead body. The first column aperture is positioned offset from the central axis, and the second column aperture is positioned asymmetrically on the opposite side. This asymmetric arrangement allows the crosshead to accommodate universal testing machine columns while using a simpler, lighter rectangular crosssection rather than requiring heavy offset cast portions.
2Adaptability or versatility
If special casting shapes are used for crossheads with offset column locations, then the correct shape for universal test machine compatibility is achieved, but pattern charges and storage fees increase costs
Solution Approach 1:
The crosshead design achieves universality by using a standard rectangular crosssection that can be manufactured from common steel plate stock. The asymmetric column aperture locations provide the necessary adaptability for universal testing machine compatibility without requiring specialized casting shapes. This multi-functional approach allows the same basic crosshead design to work with different column configurations while maintaining manufacturing simplicity.
Solution Approach 2:
The invention replaces expensive special castings with cheaper rectangular steel plate stock. By using readily available rectangular material and cutting/aperturing it to the required asymmetric dimensions, the design eliminates the need for costly custom patterns and special casting processes, significantly reducing upfront manufacturing costs.
3Ease of manufacture
If rectangular steel plate is used instead of special casting, then material cost is reduced, but modifications to universal testing machine may be required
Solution Approach 1:
The asymmetric positioning of column apertures in the rectangular crosshead is specifically designed to match standard universal testing machine column locations. By carefully selecting the asymmetric aperture positions, the invention ensures compatibility with existing machine configurations, eliminating the need for machine modifications while maintaining the cost advantages of rectangular steel plate construction.
Data Source
AI summary
The crosshead for a universal testing machine includes a interior face which is formed at angle to the front face which is typically about 17°. A wedge pocket is machined with walls perpendicular to the interior face, and therefore at an angle other than perpendicular to the front surface of the crosshead. This allows a rectangular steel plate to be oriented to match the machine column locations. Therefore, the material cost is significantly reduced as no special casting shape is required.