Interlocking Fixture Plates for Fast, Repeatable Workpiece Setup
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Solution Overview
Problem
Current fixture plate systems for manufacturing and inspection processes are inflexible, requiring custom designs for different machines and not optimizing space usage, leading to inventory issues and long lead times, as they are typically one-piece and not modular, thus not accommodating varying workpiece sizes efficiently.
Innovation Solution
A modular fixture plate system comprising interlocking plates with male and female projections and recesses, secured by magnets, allowing for customizable assembly to fit specific workpiece sizes and enabling easy setup and swapping, aligning with lean manufacturing principles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one-piece fixture plates are used to ensure stability and simplicity, then manufacturing precision and reliability are improved, but adaptability and ease of operation deteriorate due to inability to accommodate different workpiece sizes and machines
Solution Approach 1:
The fixture plate is divided into multiple modular segments that can be independently selected and combined. Each segment contains standardized threaded holes and can be attached to adjacent segments to create custom-sized fixture plates tailored to specific workpiece dimensions and machine requirements.
Solution Approach 2:
The fixture plate system transitions from a static one-piece design to a dynamic reconfigurable system where segments can be easily assembled and disassembled. This allows the fixture plate configuration to adapt dynamically to different workpiece sizes and inspection requirements.
2Manufacturing precision
If custom fixture plates are manufactured for different inspection machines, then manufacturing precision is improved, but loss of time and device complexity increase due to inventory management and custom manufacturing requirements
Solution Approach 1:
A universal set of standardized fixture plate segments is designed that can be used across multiple inspection machines and for various workpiece types. The segments feature standardized threaded hole patterns and connection mechanisms that work universally, eliminating the need for custom-manufactured fixture plates for each machine.
Solution Approach 2:
The modular segments are pre-designed with standardized features and connection interfaces during the product development phase. This preliminary standardization enables rapid assembly of custom fixture configurations without requiring custom manufacturing lead times when new workpiece types or machines are introduced.
3Adaptability or versatility
If large fixture plates are provided to accommodate various workpiece sizes, then adaptability is improved, but loss of substance increases due to unused surface area
Solution Approach 1:
Instead of providing one large fixture plate with much unused surface area, the system segments the fixture into multiple smaller modules. Only the necessary number and size of segments are assembled to match the actual workpiece dimensions, minimizing unused surface area and material resources.
Solution Approach 2:
The fixture plate configuration is optimized locally for each specific workpiece by assembling only the required segments. This ensures that the fixture plate surface area matches the workpiece size, eliminating wasted space and resources while maintaining full adaptability across different workpiece sizes.
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 modular system facilitates fast, easy, and repeatable setups, reduces resource usage, and enhances equipment value by allowing for flexible configurations that match workpiece sizes, improving production efficiency and minimizing setup times.
Implementation Method 1
secured by magnets
Data Source
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AI summary
A modular fixture plate system comprising: at least one interlocking fixture plate comprising at least one of a male end and a female end, wherein the male end comprises at least one male projection and the female end comprises at least one female recess; and a docking plate comprising at least one of at least one male projection and at least one female recess; wherein at least one male projection or female recess of the at least one interlocking fixture plate is interlocked with a mating one of the at least one male projection or the at least one female recess of the docking plate.