Generator Mounting Frame Assembly Using Rigid Fixture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for assembling a mounting frame for machines like generators are costly and require extensive machining to ensure precise alignment and flatness of mounting surfaces, which can be error-prone and time-consuming.
Innovation Solution
A method involving a rigid fixture member with locating surfaces that holds mounting surfaces in fixed positions, allowing for accurate assembly without further machining, where the mounting surfaces are positioned by abutting against these locating surfaces and fixed through bonding, such as welding, to the mounting members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding and machining methods are used to assemble the mounting frame, then the mounting surfaces can be made flat and level, but the process requires expensive machining operations and extensive time
Solution Approach 1:
The fixture member is prepared in advance with precise locating surfaces that define the correct positions and orientations of mounting surfaces. By pre-configuring the fixture with these accurate reference surfaces, the mounting surfaces are positioned correctly during assembly without requiring subsequent machining operations to achieve flatness and levelness
Solution Approach 2:
The fixture member acts as an intermediary tool that temporarily holds the mounting surfaces in their correct relative positions during assembly. The locating surfaces on the fixture serve as a mediator to transfer precise positioning information to the mounting surfaces, eliminating the need for expensive post-assembly machining
2Manufacturing precision
If traditional welding and machining methods are used to assemble the mounting frame, then the mounting surfaces can be positioned correctly, but the process becomes costly and time-consuming
Solution Approach 1:
The fixture member with locating surfaces serves as a positioning intermediary that simplifies the manufacturing process. Instead of requiring complex machining operations to achieve precise positioning, the fixture provides ready-made reference surfaces that guide the assembly, reducing both cost and complexity
Solution Approach 2:
The locating surfaces on the fixture member replicate the desired final positions and orientations of the mounting surfaces. By copying the correct geometric relationships into the fixture's locating surfaces, the invention eliminates the need for expensive precision machining of the final product
3Manufacturing precision
If mounting surfaces are machined to fixed critical dimensions, then precise alignment can be achieved, but the process requires detailed instructions and operator accuracy
Solution Approach 1:
The fixture member with locating surfaces acts as a physical intermediary that encodes the correct alignment information. Instead of relying on complex procedures and operator skill to achieve precise alignment through machining, the fixture's locating surfaces physically guide the mounting surfaces into correct positions, simplifying the assembly procedure
Solution Approach 2:
The fixture member performs the alignment function automatically through its locating surfaces. The geometry of the locating surfaces self-adjusts to guide the mounting surfaces into correct positions without requiring detailed instructions or high operator skill, making the process more foolproof
Data Source
AI summary
A mounting frame for a machine such as a generator is assembled by first positioning the mounting surfaces (18, 20) against locating surfaces (8) on a rigid fixture member (2). The mounting frame (16, 10, 22, 40, 26) is then constructed to fix the positions of the mounting surfaces, and the fixture is removed. Thus the surfaces require no further machining to be aligned accurately in the correct relative positions.