Flexible Part Processing Without Custom Jig Alignment
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Solution Overview
Problem
The manufacturing of flexible parts is challenging due to their inherent deformation and the need for precise shaping, which requires custom jigs for constraining them, leading to time-consuming and error-prone processing.
Innovation Solution
A system and method that securely holds flexible parts in an unconstrained position using a holder and an end effector, with a controller guiding the positioner for relative movement based on comparisons between the part's unconstrained shape and design specifications, allowing for processing such as drilling, milling, and inspection without the need for precise jig alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom jigs are used to constrain flexible parts during processing, then manufacturing precision is improved, but device complexity and preparation time increase
Solution Approach 1:
The patent extracts the constraining function from custom jigs and transfers it to the flexible part itself through self-constraint features. The part is designed with integral constraint elements that allow it to self-restrain during processing, eliminating the need for external custom jigs while maintaining manufacturing precision.
Solution Approach 2:
Instead of using external jigs to constrain the part, the invention inverts the approach by making the part self-constraining through integral constraint features. The part's own geometry is used to provide the constraining action, reversing the traditional master-apprentice relationship between jig and part.
2Manufacturing precision
If custom jigs are used to hold flexible parts, then manufacturing precision is improved, but productivity decreases due to time-consuming setup
Solution Approach 1:
The constraint features are built into the part design beforehand, so no time-consuming jig setup is needed during processing. The self-constraint mechanism is prepared in advance as part of the part geometry, allowing immediate processing upon positioning.
Solution Approach 2:
The self-constraint features can be used with multiple different processing operations and equipment, replacing the need for multiple custom jigs for different operations. A single part design works with various end effectors and processing methods.
3Ease of operation
If flexible parts are processed in unconstrained position, then ease of operation is improved, but manufacturing precision deteriorates due to part deformation
Solution Approach 1:
The self-constraint features create preliminary counteracting forces that prevent deformation during processing. The integral constraint elements generate forces that oppose gravitational and handling-induced deformations, maintaining shape accuracy while allowing easy handling.
Solution Approach 2:
The self-constraint mechanism dynamically adapts to the part's position and deformation state, providing constraint forces as needed. The flexible constraint features can deform slightly to accommodate positioning variations while maintaining adequate constraint to prevent excessive deformation.
Data Source
AI summary
A system and method for processing a flexible part comprising holding the flexible part securely in an unconstrained position using a holder; and controlling a positioner to process the flexible part based on a comparison of a shape and/or position of the flexible part in the unconstrained position with design specifications of the part not in the unconstrained position.