Layered Noncontact Support Platform for Flexible Workpiece Flatness
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Solution Overview
Problem
Flexible workpieces are prone to bending or dimpling when supported by noncontact platforms with non-uniform air cushions, risking contact with the tabletop and affecting manufacturing or inspection processes.
Innovation Solution
A noncontact support system with a layered structure of pressure and vacuum conduits arranged in offset grid patterns, including flow restrictors and self-adaptive segmented orifice flow restrictors, to create a uniform air cushion and prevent contact, featuring service holes for fastening and sensor insertion without interfering with the conduit layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a noncontact support platform uses a simple air cushion with pressure ports, then the structure is simple and easy to manufacture, but the air cushion is non-uniform causing flexible workpieces to bend or dimple
Solution Approach 1:
The air cushion system is segmented into multiple functional layers: a pressure conduit layer with grid-pattern conduits, a vacuum conduit layer with offset grid-pattern conduits, and a port layer with interspersed pressure and vacuum ports. This segmentation allows independent optimization of pressure distribution and vacuum distribution to achieve uniform air cushion thickness while maintaining manufacturing simplicity through modular layer assembly.
Solution Approach 2:
The solution transitions from a single-layer pressure system to a multi-layer three-dimensional structure. The vacuum conduit layer is laterally offset from the pressure conduit layer, creating a staggered three-dimensional arrangement that improves air cushion uniformity. This dimensional change allows the system to achieve better workpiece support without increasing in-plane complexity.
2Object-affected harmful factors
If the air cushion thickness is increased to prevent workpiece contact, then contact risk is reduced, but flexible workpieces still bend or dimple due to non-uniform support
Solution Approach 1:
The system applies local quality by distributing pressure and vacuum ports in an interspersed pattern across the tabletop surface. Each local region receives coordinated pressure and vacuum action, creating locally uniform air cushion thickness. This local optimization prevents both contact risk and workpiece deformation by ensuring consistent support across the entire workpiece surface.
Solution Approach 2:
The system changes the physical parameters of the air cushion by introducing vacuum suction in addition to pressure airflow. The vacuum ports create negative pressure regions that work in conjunction with positive pressure regions to stabilize air cushion thickness. This parameter change from single-pressure to pressure-vacuum duality enables uniform support that prevents both contact and deformation.
3Manufacturing precision
If uniform air cushion is achieved through complex conduit arrangements, then workpiece support quality improves, but device complexity increases
Solution Approach 1:
Both the pressure conduit layer and vacuum conduit layer use the same grid-pattern conduit design, making the conduit structure universal and interchangeable. This universality simplifies manufacturing and assembly while achieving complex uniform support. The repeated modular pattern reduces design complexity despite the multi-layer structure.
Solution Approach 2:
The system employs a nested multi-layer structure where the vacuum conduit layer is positioned beneath and offset from the pressure conduit layer, which in turn is beneath the port layer. This nesting arrangement allows compact integration of multiple functions (pressure delivery, vacuum delivery, port distribution) in a vertically stacked configuration, reducing horizontal space requirements and simplifying overall system integration.
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 system ensures precise and uniform support of flexible workpieces, reducing deformation and preventing contact with the tabletop, thereby enhancing the reliability of manufacturing and inspection processes.
Implementation Method 1
A noncontact support platform typically includes a tabletop that is configured to form an air cushion above the tabletop
Implementation Method 2
vacuum ports to which suction is applied are interspersed among the pressure ports
Data Source
AI summary
A noncontact support system includes a table with a port layer having a pattern of interspersed pressure ports and vacuum ports. A pressure conduit layer includes a grid pattern of pressure conduits, connectable to a pressure source, each of the pressure ports being located on an axis passing through an intersection of at least two of the pressure conduits and substantially orthogonal to the grid pattern of pressure conduits. A vacuum conduit layer includes a grid pattern of vacuum conduits, connectable to a suction source, each of the vacuum ports being located on an axis passing through an intersection of at least two of the vacuum conduits and substantially orthogonal to the grid pattern of vacuum conduits. The grid pattern of vacuum conduits is laterally offset from the grid pattern of pressure conduits such that each intersection of pressure conduits is laterally offset from all intersections of the vacuum conduits.