Indicator Setup Block With Precision Bore for On-Machine Inspection
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Solution Overview
Problem
Current methods for measuring work piece dimensions on machine tools are prone to human error and are not suitable for large or oversized pieces, as they require skilled operators and specific machine tools, leading to inefficiencies and inaccuracies.
Innovation Solution
A precision machined internal diameter gage device that aligns a test indicator with the spindle centerline, using magnetic attraction for stability and a precision bore for radial measurement, allowing for accurate measurement of surfaces and accommodating large work pieces without distorting or damaging them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hand tools like micrometers are used to measure work pieces, then measurements can be taken, but human error is introduced and accuracy is reduced
Solution Approach 1:
The measurement system performs self-verification through the test indicator comparing the precision bore against the spindle centerline automatically. The device self-aligns and self-measures without requiring manual operation or interpretation by operators, eliminating human error while maintaining measurement accuracy.
Solution Approach 2:
The patent replaces manual mechanical measurement tools (micrometers, calipers) with a machine tool-integrated test indicator system. This substitution transitions from operator-dependent mechanical measurement to machine-driven automated measurement, eliminating human error and improving reliability.
2Measurement precision
If tool probes are used for on-machine measurement, then measurements can be taken, but costly machine-specific hardware and software are required
Solution Approach 1:
The device uses a universal precision bore that can be used with any machine tool spindle, eliminating the need for machine-specific tool probes. The same device works across different machine tools without requiring specialized hardware or software, providing universal on-machine measurement capability.
Solution Approach 2:
The patent extracts the measurement reference (precision bore) from the machine-specific tool probe system. By using a standalone precision bore that can be measured by any test indicator, the system removes the dependency on expensive machine-specific hardware and software while maintaining measurement capability.
3Stability of the object's composition
If magnetic inserts are added to the device, then magnetic attraction prevents device movement, but the magnetic inserts must not distort the device's flatness
Solution Approach 1:
The magnetic inserts are placed in localized recesses at specific positions on the device rather than being distributed throughout. This local placement provides magnetic attraction for stability while concentrating the magnetic material only where needed, preventing distortion of the overall device flatness.
Solution Approach 2:
The magnetic inserts are nested within recesses in the device structure. This nesting approach allows the magnetic material to be contained within the device body without protruding or distorting the external flat surfaces, maintaining both stability and manufacturing precision.
4Measurement precision
If the precision bore radius is used for measurement calculation, then accurate radial measurements are obtained, but the bore must be precisely manufactured to nominal size
Solution Approach 1:
The precision bore is pre-manufactured to a known nominal size with controlled tolerance. This preliminary precision manufacturing creates a reference standard that can then be used for subsequent measurements, allowing the bore radius to serve as an accurate reference for radial measurement calculations.
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 device provides repeatable and accurate measurements, reducing human error and thermal variations, and is versatile across different machine tools, enabling precise inspection and setup of work pieces without the need for costly tool probes.
Implementation Method 1
The device locates on any planar surface on a machine tool with a magnetic attraction to prevent the device from moving. Magnetic inserts recessed on the bottom of the device provide this magnetic attraction
Data Source
AI summary
The invention of a device has four threaded bolts that engage cooperatively threaded apertures in a base. These thread bolts hold the device in a temporary yet stationary position. The device has non-magnetic metal which allows test indicators to display accurate results free from any magnetic fields. The device has a precision bore of a nominal size. The radial value of the nominal size precision bore provides for mathematical calculation of the spindle centerline to work piece distance for measuring. The device has undercuts on both of its sides to aid in removing by hand. These undercuts allow the device to pivot from its stationary position for removal without damaging the planar surface. Alternatively, the device has four magnetic inserts, pocketed upwardly from the bottom surface.