Independent Axis Clamping Roller for Complex Workpiece Contours

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Solution Overview

Problem

Existing clamping devices for manufacturing tools, such as those used in friction stir welding, are constrained to follow the tool's path and fail to apply clamping force effectively on workpieces with complex geometries and varying orientations.

Innovation Solution

A clamping apparatus mounted on a common support with a tool, allowing independent movement along at least one axis, equipped with clamping rollers and a rotary drive for programmable force application, coordinated with the tool's movement to track the workpiece's contours.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the clamping device is constrained to follow the tool's path, then the device structure is simple, but the clamping device cannot track the workpiece contours effectively on complex geometries

Engineering Contradiction:

Improveclamping device tracking capabilityVSAvoidclamping device structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The clamping device is segmented into independent movable components including a clamping roller mounted on a movable carriage that can travel along the workpiece contour independently of the tool path. This segmentation allows the clamping mechanism to adapt to complex geometries while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The clamping device is merged with the tool assembly, sharing common support structures and control systems. The clamping roller and tool are both mounted on the movable carriage, allowing them to move together while the clamping portion can independently follow the workpiece contour.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If the clamping device is mounted on a common support with the tool, then the overall system structure is compact, but the clamping device cannot move independently to apply force at desired locations

Engineering Contradiction:

Improveindependent movement capabilityVSAvoidmovement mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The clamping device incorporates dynamic movement capabilities where the clamping roller is mounted on a movable carriage that can travel along guides to follow the workpiece contour. This dynamic structure allows independent movement of the clamping portion relative to the tool while maintaining compact integration.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The clamping device adds an independent degree of freedom by allowing the clamping roller to move along the workpiece contour in a direction independent of the tool's primary movement axis. This dimensional independence enables the clamping force to be applied at desired locations regardless of tool orientation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Force

If traditional clamping devices are used, then the friction between clamping elements and workpiece is high, but this increases the force required and reduces clamping effectiveness

Engineering Contradiction:

Improveclamping force efficiencyVSAvoidfriction

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The clamping roller incorporates vibration mechanisms that oscillate the roller surface during contact with the workpiece. This vibration reduces friction between the clamping elements and workpiece surface, allowing effective clamping with reduced force requirements and preventing damage to sensitive workpieces.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The traditional direct mechanical contact clamping is replaced with a roller-based system that reduces friction through rolling contact. The clamping roller rotates during engagement, substituting sliding friction with rolling friction, which significantly reduces the force required and improves clamping effectiveness.

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

Enables precise and adaptable clamping force application on complex workpieces, reducing the need for external clamping tools and ensuring consistent clamping across varying orientations and tool paths.

Implementation Method 1

a pneumatically driven slide for applying a programmable amount of pressure to the workpiece

Methodology Applied

Scientific EffectPneumatics: Pressurisation

Implementation Method 2

clamping rollers that roll along the surface of the workpiece in order to reduce friction

Methodology Applied

Scientific EffectRolling friction: Roller

Data Source

PatentUS7774910B2Independent axis clamping apparatus and method

Publication Date: 2010.08.17 THE BOEING CO

AI summary

Apparatus for performing operations on a workpiece includes a clamping assembly mounted on a tool support for movement along at least one axis independent of the axes along which the tool moves. The clamping assembly includes clamping devices for applying clamping pressure to the workpiece, and a rotary drive mounted on the tool support for rotating the clamping devices around the independent axis. The clamping devices include clamping packs having a clamping roller mounted on a pneumatically driven slide for applying a programmed amount of clamping pressure to the workpiece.