Leveler Table Recessed Circular Level for Precision Alignment
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Solution Overview
Problem
Existing leveler tables fail to consistently achieve a level condition with respect to both x and y coordinates, leading to variations in product quality, particularly in manufacturing processes like producing automotive windshield sensor pads, where a level surface is crucial for uniformity and reliability.
Innovation Solution
A leveler table design incorporating a recessed circular level within the center of the plate, secured in an interference fit, allows for precise adjustment of the top surface using three spaced screws, ensuring the work surface is level and repeatable, with the circular level's central location providing visual confirmation of level orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a circular level is placed on the work surface, then the user can visually confirm level orientation, but the level may interfere with product manufacturing or cause inconsistency in achieving level condition
Solution Approach 1:
The circular level is recessed into the plate, creating a nested structure where the level is housed within a dedicated cavity. This nesting approach allows the level to be integrated into the work surface without interfering with product manufacturing, while still providing visual confirmation of level orientation through the bubble indicator visible at the recessed level's top surface.
Solution Approach 2:
The recessed structure acts as an intermediary between the circular level and the work surface. By providing a dedicated recessed housing, the level is positioned at a specific depth that allows it to function as a mediator - providing visual feedback without directly contacting or interfering with the workpiece being manufactured on the plate.
2Ease of manufacture
If the circular level is mounted on the surface, then it provides visual feedback, but it may not provide accurate reference for level adjustment
Solution Approach 1:
The recessed circular level is positioned such that its top surface is coplanar with the top surface of the plate, creating an equipotential reference plane. This ensures that the bubble indicator in the circular level accurately reflects the level condition of the work surface, providing both visual feedback and precise reference for adjustment.
3Ease of operation
If three spaced screws are used for adjustment, then the plate can be leveled, but achieving consistent level orientation across multiple uses is difficult
Solution Approach 1:
The recessed circular level provides immediate visual feedback through its bubble indicator, showing the user whether the plate is level in multiple orientations. This feedback mechanism allows the user to adjust the three spaced screws until the bubble is centered, ensuring consistent and repeatable level orientation across multiple uses.
Solution Approach 2:
The circular level is pre-installed in a recessed position with its top surface coplanar with the plate surface, providing a ready-to-use reference system before manufacturing begins. This preliminary setup eliminates the need for separate level checking tools and ensures consistent reference planes for repeated manufacturing operations.
Data Source
AI summary
A leveler table includes a plate with a flat top work surface that is level in all planes, by locating a circular level recessed within the center of the plate, so that the level indicator of the circular level is in horizontal alignment with the top work surface. By locating the circular level in the middle of the plate, at the same horizontal level as the work surface, this leveler table provides accuracy and repeatability for use of the flat top work surface in manufacturing steps, particularly the forming of parts where repeatability is necessary, such as the in situ forming of an automotive windshield sensor pad in an open ended package supported on the flat top surface.