Manufacturing frame
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Solution Overview
Problem
Existing manufacturing processes face challenges in securely positioning and maintaining the tension of flexible materials during operations across multiple stations, leading to potential defects and inefficiencies due to cumbersome and error-prone systems.
Innovation Solution
A frame with alignment tabs and a tensioning element that securely positions flexible materials at known locations across multiple manufacturing stations, allowing for precise alignment and tension management without visual inspection, using alignment elements to define an origin and maintain material position during sequential operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If station-specific equipment (clips, pincers, pins) is used to secure materials at each manufacturing station, then the materials can be secured during operations, but the system becomes cumbersome and complicated
Solution Approach 1:
The frame serves as a universal securing mechanism that can be used across multiple manufacturing stations and operations. Instead of having station-specific clips, pincers, or pins, a single frame structure with alignment tabs and tensioning elements provides consistent material securing functionality throughout the entire manufacturing process, reducing the variety and complexity of securing devices needed.
Solution Approach 2:
The frame is divided into functional segments including alignment tabs for positioning and tensioning elements for securing materials. This segmentation allows each component to perform its specific function efficiently while contributing to the overall material security across multiple stations without requiring a completely separate system at each location.
2Manufacturing precision
If human operators position and maneuver work materials at each station, then the materials can be positioned accurately, but the process becomes error-prone and time-consuming
Solution Approach 1:
The frame with alignment tabs is prepared in advance with predefined positioning features that guide material placement. The alignment tabs are designed with specific geometries that automatically orient and position materials correctly when engaged, eliminating the need for operators to manually position and adjust materials at each station, thereby reducing both time and potential for error.
Solution Approach 2:
The alignment tabs serve as intermediary elements between the frame and the manufacturing stations. These tabs provide a mechanical interface that translates the frame's predefined geometry into accurate material positioning, acting as a mediator that ensures precise placement without requiring direct human intervention or complex vision systems.
3Measurement precision
If vision systems or human operators are used to place landmarks on work materials, then the position can be determined, but the system becomes more complicated and prone to error
Solution Approach 1:
The frame with alignment tabs is self-aligning through its geometric design. The tabs are configured to automatically engage with corresponding features on the frame or manufacturing station, providing self-positioning functionality without requiring external vision systems or human operators to place and read landmarks. The system determines its own position through mechanical engagement of the alignment features.
4Adaptability or versatility
If materials are moved between manufacturing stations, then different operations can be performed, but the position and tension of materials must be reassessed and repositioned
Solution Approach 1:
The frame is pre-configured with alignment tabs and tensioning elements that maintain material position and tension settings across multiple stations. The alignment features are designed in advance to be compatible with the frame structure, allowing materials to be transferred between stations without requiring reassessment or repositioning, as the frame itself carries the positioning information and mechanical constraints.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A manufacturing frame (230) comprises one or more alignment tabs (330). Each alignment tab comprises an alignment element (340a). The alignment element interacts with a corresponding alignment element (520a) at a manufacturing station (500) to identify to the manufacturing station the position and orientation of the frame. The frame supports a flexible material (205) in a known position and orientation relative to the frame, allowing the manufacturing station to infer the position and orientation of the flexible material on the frame from the interaction of the alignment elements on the frame and the manufacturing station.