Flexible Welding Fixture for Compact RV Frame Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing method of stack welding for assembling recreational vehicle frames requires significant space, is cumbersome due to the weight and size of master frames, and leads to storage and handling issues, as well as frame warping over time.

Innovation Solution

A flexible welding fixture with a reconfigurable substrate and guide surfaces that align frame members for welding, including heat dispersing patches and visual guides, allowing for compact storage and easier handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If stack welding method is used with master frames, then frame members can be welded together to form structural frames, but significant storage space is required and handling becomes cumbersome

Engineering Contradiction:

Improveframe assembly capabilityVSAvoidstorage space

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The master frame is segmented into multiple individual frame members that can be independently stored and transported. These members are then assembled on a welding table with fixturing devices that provide alignment and positioning without requiring a complete master frame structure, thereby reducing storage space requirements while maintaining manufacturing capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of storing and transporting heavy master frames, the patent uses lightweight fixturing devices and alignment tools that replicate the positioning function of master frames. These copying devices can be easily stored and transported, then used to establish the correct geometry for welding frame members without requiring the original master frame structure

Inventive Principle:

Principle #26Copying

2Area of stationary object

If master frames are stored in stacked leaning arrangement, then storage space is utilized, but frames tend to bend and warp over time

Engineering Contradiction:

Improvestorage space utilizationVSAvoidframe dimensional stability

Core Design Contradiction:

Area of stationary objectVSStability of the object's composition

Solution Approach 1:

The patent employs disposable or easily replaceable fixturing devices and alignment tools made from lightweight materials instead of durable master frames. These temporary fixtures are used only during the welding process and then discarded or stored compactly, eliminating the need for long-term storage of heavy master frames that are prone to warping when stacked

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the physical state and properties of the fixturing system from permanent, heavy master frames to temporary, lightweight positioning devices. This parameter change allows the fixtures to be used during welding but eliminates the storage and stability issues associated with long-term master frame storage

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If master frames are used for fixturing, then frame members can be aligned for welding, but the weight and size make handling unwieldy

Engineering Contradiction:

Improveframe member alignmentVSAvoidhandling ease

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent replaces the heavy mechanical master frame system with a combination of welding table fixturing devices, alignment tools, and positioning fixtures. These substituted mechanical elements provide the necessary alignment and positioning functions but with significantly reduced weight and improved handling characteristics, allowing operators to easily position and adjust frame members during welding

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The flexible welding fixture reduces space requirements, simplifies handling, and minimizes frame warping by aligning frame members efficiently for welding, facilitating easier assembly and maintenance while eliminating the need for master frames.

Implementation Method 1

The flexible substrate comprises a fiber reinforced sheet of material, such as a fiber reinforced sheet of vinyl

Methodology Applied

Scientific EffectFiber reinforcement: Composite Materials

Implementation Method 2

a plurality of patches of heat dispersing material located on the flexible substrate in locations to correspond to the weld points to disperse heat from the welding at the weld points

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS10960499B2Flexible welding apparatus

Publication Date: 2021.03.30 THOR TECH CORP

AI summary

A welding fixture includes a flexible substrate, which is sufficiently flexible to be reconfigurable between a planar configuration and a folded or rolled compact configuration and is dimensioned to support a plurality of frame members to form a structural frame for a recreational vehicle (RV). The welding fixture further includes a plurality of guide surfaces mounted to the flexible substrate, which are arranged on the flexible substrate to align the frame members in a predefined arrangement with a plurality of weld points and to align the frame members in the predefined arrangement while being welded together at the weld points.