Laser-Cut Checking Fixture for Automotive Inspection

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Solution Overview

Problem

The existing manufacturing methods for checking fixtures in the automotive industry are complex and expensive, requiring milling machines and resulting in long lead times, making it necessary to develop a simpler and faster method for producing these fixtures.

Innovation Solution

A checking fixture is manufactured using laser-cut sheet material for the metallic support sheet and reinforcement structure, allowing for precise placement of holder members without the need for expensive milling techniques, and utilizing welding for reinforcement and attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If milling technique is used to manufacture checking fixtures from a large block of material, then manufacturing precision can be achieved, but device complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improvechecking fixture precisionVSAvoidmilling machine complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The checking fixture is divided into multiple components: a base plate, support sheets with through-holes, and holder members. These segmented parts are manufactured separately using simpler laser cutting technology and then assembled together, avoiding the need for complex milling operations on a single large block while maintaining overall precision

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional mechanical milling process is replaced with laser cutting technology. The laser cutting system uses optical energy to cut and shape the metallic sheets and support structures, substituting a complex mechanical milling machine with a more versatile and simpler laser cutting system that achieves comparable precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If milling technique is used to manufacture checking fixtures, then manufacturing precision can be achieved, but manufacturing time increases

Engineering Contradiction:

Improvechecking fixture precisionVSAvoidmanufacturing lead time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

By segmenting the fixture into separately manufacturable components (base plate, support sheets, holder members), each part can be cut quickly using laser technology and then rapidly assembled, dramatically reducing the total manufacturing time compared to milling the entire fixture as one piece

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Replacing the time-consuming milling process with faster laser cutting technology enables quick production of fixture components, reducing manufacturing lead time while maintaining the required precision through laser's inherent accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If a new checking fixture is designed for every vehicle component, then measurement precision is maintained, but manufacturing cost increases

Engineering Contradiction:

Improvevehicle component inspection accuracyVSAvoidfixture manufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The base plate and support sheets are designed as universal components with standardized through-holes and mounting features that can accommodate different holder members for various vehicle components. This modular universal design allows the same basic structure to be used for inspecting multiple different components, reducing the need to manufacture entirely new fixtures for each application

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The fixture is segmented into a universal base structure and interchangeable holder members. The universal base plate and support sheets provide the measurement framework, while specific holder members can be attached or removed based on the component being inspected, allowing one fixture body to serve multiple measurement purposes

Inventive Principle:

Principle #1Segmentation

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 approach enables the production of checking fixtures with high precision and versatility, reducing manufacturing time and costs while maintaining the stability and accuracy required for inspecting vehicle components.

Implementation Method 1

the cutting may be produced by the laser melting the material

Methodology Applied

Scientific EffectLaser melting: Laser Ablation

Implementation Method 2

utilizing welding for reinforcement and attachment

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS10625799B2Checking fixture

Publication Date: 2020.04.21 VOLVO CAR CORP

AI summary

The present invention relates to a checking fixture comprising: a bottom support frame; a metallic support sheet mechanically fixated to the bottom support frame, the metallic support sheet comprising a plurality of through holes arranged in a predetermined layout; a plurality of holder members for holding vehicle component holders or vehicle component measurement devices, the holder members being attached to the metallic support sheet in the through holes and being adapted to extend away from an upper surface of the metallic support sheet; at least one metallic sheet reinforcement structure arranged orthogonally separated from the metallic support sheet, the metallic sheet reinforcement structure being adapted to fixate the relative position of at least two of the holders members. The metallic support sheet and the metallic reinforcement sheet structure are made from laser cut sheet material.