Fixed Square Assembly Using Reamed Holes for Right-Angle Accuracy
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Solution Overview
Problem
Conventional methods for manufacturing fixed squares face challenges in achieving precise alignment and attachment of blades and stocks made from different materials, leading to low yield and potential angular inaccuracies over time.
Innovation Solution
The method involves providing pre-made holes in both the blade and stock, aligning them in a fixture, enlarging these holes using a reamer, and attaching them with fastening elements like pins or rivets, ensuring accurate and strong assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If three holes are drilled through the blade and stock using conventional drilling methods, then the blade and stock can be joined with pins, but the manufacturing precision is difficult to achieve due to tight tolerances and working with two different materials
Solution Approach 1:
The patent applies preliminary action by providing pre-made holes in both the blade and stock before assembly. These pre-made holes are designed with specific dimensions and positions to facilitate accurate alignment. The holes are enlarged using a reamer to remove burrs and achieve precise cylindrical surfaces, enabling accurate pin insertion without the difficulty of drilling through two different materials simultaneously.
Solution Approach 2:
The manufacturing process is segmented into distinct steps: providing pre-made holes in separate components (blade and stock), aligning them in a fixture, enlarging the holes with a reamer, and finally inserting pins. This segmentation allows each operation to be optimized independently, avoiding the complexity of simultaneous multi-material drilling.
2Productivity
If conventional drilling methods are used to create holes in different materials, then the blade and stock can be attached, but the yield is low due to difficulty in achieving precise results
Solution Approach 1:
The blade and stock are provided with pre-made holes before assembly, allowing each component to be prepared separately with high precision. This preliminary preparation eliminates the yield loss associated with difficult multi-material drilling, as each hole is created in a single material using optimized processes.
Solution Approach 2:
A fixture is introduced as an intermediary device to hold the blade and stock in a right angle relationship during assembly. The fixture ensures accurate alignment of the pre-made holes from both components, enabling consistent and precise pin insertion without requiring complex drilling operations through different materials.
3Reliability
If three pins are inserted into drilled holes to join the blade and stock, then the square can be assembled, but the angular accuracy may not be maintained over time due to insufficient fastening strength
Solution Approach 1:
The patent changes the dimensional parameters of the holes by enlarging them using a reamer. The reamer increases the hole diameter and creates a precise cylindrical surface with removed burrs. This parameter change allows for larger, more robust fastening elements that provide sufficient attachment strength to maintain angular accuracy over time, while the precise hole geometry ensures accurate pin insertion.
4Manufacturing precision
If drilling is performed without pre-made holes, then the process follows conventional methods, but excessive shavings are generated creating a dirty environment that affects attachment accuracy
Solution Approach 1:
The blade and stock are provided with pre-made holes before assembly, so that when the holes are enlarged with the reamer during assembly, the amount of material removal (shavings) is minimized. The pre-made holes already contain the majority of the material removal, and the reaming operation only needs to enlarge and finish the surfaces, generating significantly fewer shavings and a cleaner working environment.
Data Source
AI summary
A method of manufacturing a fixed square includes providing a blade of the square, where the blade includes at least three first holes; providing a stock of the square, where the stock includes at least three second holes corresponding to the at least three first holes of the blade for attaching the blade and the stock to each other; holding the provided blade and stock in a fixture in a right angle relationship where the at least three first holes of the blade align with the at least three second holes of the stock; enlarging the at least three first and second holes while the blade and the stock are held in the fixture; and attaching the blade and the stock to each other using fastening elements in the at least three enlarged first and second holes while the blade and the stock are held in the fixture.