Indexing Pin Clamp Alignment for Sleeve-Free Composite Assembly
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Solution Overview
Problem
Manufactured structures, particularly composite structures in the aerospace industry, face challenges in aligning machined openings for fastener installation due to electromagnetic environmental effects, leading to misalignment and potential damage, which is exacerbated by the need for fastener sleeves that increase weight and manufacturing costs.
Innovation Solution
The use of indexing pins with a central axis, threaded portion, stem, cylindrical surface, tapered surface, and flange, along with an indexing clamp that includes a nut and protective clamping member, to align and securely fasten structural bodies without the need for fastener sleeves by ensuring precise alignment of openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastener sleeves are used to prevent misalignment damage, then reliability is improved, but weight increases
Solution Approach 1:
The patent introduces indexing pins as intermediary alignment tools that guide fastener installation without requiring permanent fastener sleeves. The pins provide temporary mediation during assembly to ensure accurate alignment, then are removed, eliminating the need for additional weight-bearing sleeves in the final structure.
Solution Approach 2:
The indexing pins perform preliminary alignment action before fastener installation. By pre-establishing accurate positioning of structural bodies and openings, the system eliminates the need for fastener sleeves that would otherwise be required to maintain alignment during and after fastener installation.
2Reliability
If fastener sleeves are used to prevent misalignment damage, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The indexing pins serve as temporary intermediary tools during assembly rather than permanent structural components. This eliminates the need for expensive fastener sleeves that would require additional manufacturing steps, material costs, and quality control procedures for permanent installation.
Solution Approach 2:
The indexing pins are simple, inexpensive alignment tools that are used temporarily during assembly and then removed. They replace expensive permanent fastener sleeves, providing the necessary alignment function at a fraction of the cost for a single-use application.
3Manufacturing precision
If structural bodies are separated for finishing operations, then manufacturing precision is improved, but alignment precision deteriorates
Solution Approach 1:
The indexing pins establish preliminary alignment references before finishing operations separate the structural bodies. These pins serve as permanent or semi-permanent alignment fixtures that maintain the precise relative positioning established during initial assembly, enabling finishing operations to be performed on separated bodies while preserving alignment accuracy.
Solution Approach 2:
The indexing pins act as intermediary alignment references that bridge the separation between structural bodies during finishing operations. They maintain the spatial relationship and alignment between openings in different bodies, allowing high-precision finishing to be performed on separated components while ensuring accurate reassembly.
4Device complexity
If conventional fasteners are used without indexing pins, then device complexity is reduced, but alignment precision deteriorates
Solution Approach 1:
The indexing pins introduce a simple intermediary alignment mechanism that works in conjunction with conventional fasteners. Rather than replacing the entire fastening system, the pins provide a dedicated alignment function that guides fastener installation, achieving high precision without requiring complex specialized fastening hardware.
Solution Approach 2:
The patent separates the alignment function from the fastening function by introducing indexing pins as distinct alignment tools. This segmentation allows conventional fasteners to handle the load-bearing function while the indexing pins handle the precision alignment function, achieving high accuracy without requiring complex multi-functional fasteners.
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
This solution enables precise alignment of structural bodies, eliminating the need for fastener sleeves, reducing manufacturing costs and weight, while ensuring secure fastening and preventing damage during fastener installation.
Implementation Method 1
The indexing pin additionally comprises a tapered surface, extending between the threaded portion and the cylindrical surface... The indexing pin aligns a first body of a structure and a second body of the structure by urging alignment of first openings of the first body with second openings of the second body when the indexing pin is inserted through one of the first openings and a corresponding one of the second openings
Implementation Method 2
The indexing pin comprises a central axis and a threaded portion, extending along the central axis... The indexing clamp also comprises a nut, configured to be threadably coupled with the threaded portion of the indexing pin
Implementation Method 3
The indexing clamp also comprises a protective clamping member, having an external protective-clamping-member diameter and configured to be coupled to the nut and configured be located between the nut and the flange... The protectively clamping member protects the second-body second surface when the nut is preloaded against the protective clamping member
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
An indexing pin (100) comprises a central axis (154). The indexing pin (100) further comprises a threaded portion (126), extending along the central axis (154). The indexing pin (100) also comprises a stem (148), extending along the central axis (154) opposite the threaded portion (126). The indexing pin (100) further comprises a cylindrical surface (104), extending along the central axis (154) between the threaded portion (126) and the stem (148). The indexing pin (100) further comprises a tapered surface (112), extending between the threaded portion (126) and the cylindrical surface (104). The indexing pin (100) further comprises a flange (136), located between the stem (148) and the cylindrical surface (104).