Sensor-Based Fixture Tool Indexing for Continuous Manufacturing
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Solution Overview
Problem
Current manufacturing techniques require time-consuming and expensive methods for accurate indexing of workpieces, especially for large structures like aircraft parts, which hinder continuous manufacturing processes due to the need for extensive setup and lack of efficiency in moving workpieces between locations.
Innovation Solution
An indexing apparatus comprising a fixture tool, an indexing feature, and a sensor system that allows for the detection and location of the indexing feature, enabling the automated machine to accurately index relative to the fixture tool and workpiece, facilitating quick and precise movement without the need for extensive setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional probing or fixture methods are used to index workpieces, then positioning accuracy is achieved, but setup time and manufacturing cost increase significantly
Solution Approach 1:
Indexing features are pre-defined and integrated into the fixture tool design before workpiece placement. The sensor system is pre-configured to detect these features, eliminating the need for time-consuming probe measurements or complex fixture adjustments during setup. This preliminary preparation enables rapid indexing while maintaining precision.
Solution Approach 2:
The patent replaces traditional mechanical probing systems and complex physical fixtures with a sensor-based detection system. Instead of using mechanical probes to measure workpiece locations or large fixtures to constrain positioning, the system uses sensors to detect indexing features and automatically calculate workpiece locations, significantly reducing setup time while maintaining accuracy.
2Manufacturing precision
If extensive fixtures or numerous probe locations are used for large structures, then indexing accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the essential indexing function from complex mechanical fixtures and probe systems. Instead of using extensive physical fixtures or multiple probe locations, the system extracts only the critical indexing features that are integrated into the fixture tool and detected by sensors. This extraction simplifies the overall system while maintaining indexing accuracy.
Solution Approach 2:
The system uses sensor detection to create a digital representation of the indexing features and workpiece locations. This virtual model allows the automated machine to understand workpiece positioning without requiring physical measurement at multiple locations or complex mechanical constraints, reducing device complexity while maintaining precision.
3Manufacturing precision
If traditional indexing methods are used, then workpiece positioning is achieved, but continuous manufacturing capability is hindered
Solution Approach 1:
The sensor-based indexing system enables continuous operation by eliminating setup interruptions. As workpieces are moved to new locations or new workpieces are introduced, the sensor system continuously detects indexing features and automatically updates workpiece locations without stopping production. This maintains continuous manufacturing flow while ensuring accurate positioning.
Solution Approach 2:
The system transitions from static, pre-configured fixtures to a dynamic sensor-based system that can adapt to changing workpiece locations and orientations in real-time. The automated machine receives continuous location updates and adjusts its operations accordingly, enabling flexible continuous manufacturing without sacrificing positioning precision.
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 rapid and accurate indexing of workpieces, reducing setup time and costs, and allowing for continuous manufacturing by determining the fixture tool's location relative to the operation cell, thus improving operational efficiency.
Implementation Method 1
a sensor, configured to detect the indexing feature
Data Source
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Figure 3~4
AI summary
An indexing apparatus includes a fixture tool (102), movable relative to an operation cell (106), and an indexing feature (104), fixed relative to the fixture tool. The indexing apparatus also includes a sensor (184), configured to detect the indexing feature. The indexing apparatus further includes a controller (110), in communication with the sensor. The controller is configured to locate the fixture tool relative to the operation cell from an indexing-feature location (116) of the indexing feature, identified by the sensor.