Interlocking Precision Flexible Rail System for Machine Tools
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Solution Overview
Problem
Current flexible rail systems for automatic positioning tools face challenges in achieving straight, interchangeable, and flexible joints, especially in long lengths, as previous methods either compromise on straightness or interchangeability, or introduce stiffness that affects rail flexibility.
Innovation Solution
A precision flexible rail system with interlocking stepped rail elements and removable clips with pins, secured by threaded fasteners, maintains rail flexibility and straightness while allowing for interchangeability, using long stepped overlaps and strategically placed alignment pins to manage stresses and tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If rails are spliced together to achieve long lengths, then the rail extension length is improved, but the joint becomes crooked and non-interchangeable
Solution Approach 1:
The rail system is divided into modular rail elements that can be spliced together to achieve unlimited length while maintaining interchangeability. Each rail element contains integrated features (steps, clips, pins) that enable precise alignment and connection when spliced, resolving the contradiction between achieving long lengths and maintaining joint precision.
2Manufacturing precision
If sandwiching plates are used to hold the rail joint straight, then the joint straightness is improved, but the rail flexibility is reduced due to added stiffness
Solution Approach 1:
The alignment and flexibility functions are merged into the rail element itself through integrated steps and clips rather than external sandwiching plates. The clips are positioned to align the steps while allowing the rail to remain flexible, eliminating the need for stiffening plates and resolving the contradiction between joint straightness and rail flexibility.
3Adaptability or versatility
If short sandwiching clips are used, then the rail flexibility is maintained, but the interchangeability and repeatable accuracy cannot be achieved
Solution Approach 1:
The alignment pins and steps are pre-positioned on the rail elements during manufacturing to establish precise alignment relationships. This preliminary action ensures that when rail elements are spliced, they automatically align with the required accuracy for interchangeability without requiring additional alignment features that would compromise flexibility.
4Manufacturing precision
If long sandwiching plates are used, then the interchangeability and accuracy are improved, but the rail flexibility is significantly reduced
Solution Approach 1:
The clips are strategically positioned at specific locations along the rail elements where they provide alignment and connection functions without creating excessive stiffness. This localized approach allows the rail to remain flexible in regions away from the clips while maintaining precision at the connection points, resolving the contradiction between interchangeability and flexibility.
Data Source
AI summary
An interlocking precision flexible rail system for carrying a positionable machine tool employs a first rail element having a first step on a lower surface extending from a first end to a termination at a predetermined length and a second rail element having a mating step on an upper surface extending from a second end to receive the first step. A pair of first clips is removably affixed to a top surface of the first rail element adjacent the first end with a first pin and to the second rail element with a second pin in each clip. A pair of second clips is removably affixed to a bottom surface of the second rail element adjacent the second end with a third pin and to the first rail element with a forth pin in each clip. Alignment holes to receive the pins have tolerances defined in conjunction with the predetermined length of the step, the length of the step allowing a reduced tolerance. The first and second pairs of clips and associated pins laterally secure the rail elements in mated engagement.