Modular Fabrication Fixture for Moving Partially Welded Workpieces
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Solution Overview
Problem
Moving large and heavy partially welded workpieces is costly and time-consuming, and they are prone to deformation and shear stress failure due to immense stresses developed during handling, as existing methods require temporary strengthening beams and extensive analysis for safe movement.
Innovation Solution
A fabrication fixture comprising independently adjustable supports and modular housings that envelop the workpiece, allowing for secure retention and movement by eliminating movement in degrees of freedom, with adjustable supports and end stops to prevent deformation and stress, and a method for rotating and transposing workpieces using lifting mounts and reversible connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temporary strengthening beams are welded to large partially welded workpieces to counteract shear forces, then the workpiece can be moved safely, but the manufacturing cost increases and time is consumed for welding and subsequent removal of beams
Solution Approach 1:
The patent introduces a fabrication fixture as an intermediary device that provides external support and stabilization to the workpiece during movement. The fixture acts as a mediator between the workpiece and the handling system, eliminating the need for temporary strengthening beams to be welded to the workpiece itself. The fixture encompasses the workpiece and provides the necessary structural support through its own framework.
Solution Approach 2:
The fabrication fixture is divided into multiple components including a base, vertical walls, and adjustable support members that can be independently positioned. This segmentation allows the fixture to be configured to match different workpiece geometries and provides flexible adjustment capabilities without requiring permanent modifications to the workpiece.
2Stability of the object's composition
If temporary strengthening beams are welded to large partially welded workpieces, then structural stability is improved, but additional manufacturing steps and costs are incurred for beam removal and surface grinding
Solution Approach 1:
The fabrication fixture serves as an external intermediary structure that provides stabilization without requiring permanent attachment to the workpiece. The adjustable support members contact the workpiece at strategic locations to prevent deformation during movement, eliminating the need for welding temporary beams that would later require removal and surface preparation.
Solution Approach 2:
The fixture incorporates adjustable support members that can be dynamically repositioned along the vertical walls to accommodate different workpiece sizes and geometries. This adjustability allows the same fixture to provide optimal support for various configurations without requiring custom-built fixtures for each workpiece type.
3Reliability
If extensive analysis is performed to ensure safe movement of partially welded workpieces, then movement safety is improved, but time and resources are consumed
Solution Approach 1:
The fabrication fixture is designed with predetermined geometric features and support member configurations that are engineered to provide adequate support for partially welded workpieces. By pre-configuring the fixture with appropriate support locations and structural characteristics, the need for extensive case-by-case analysis is reduced, as the fixture itself embodies the safety requirements through its design.
4Productivity
If large workpieces are moved without adequate support, then handling time is reduced, but deformation and shear stress failure occur
Solution Approach 1:
The fabrication fixture acts as an intermediary support system that enables rapid handling of large workpieces without causing deformation. The fixture's structural framework and adjustable support members distribute loads appropriately and prevent stress concentrations that would lead to shear failure or geometric distortion during movement operations.
Data Source
AI summary
A fabrication fixture suitable for retaining a workpiece. The fabrication fixture includes a first housing having a plurality of reversibly connected modular subsections and a plurality of independently adjustable supports. A second housing has a plurality of reversibly connected modular subsections and a plurality of independently adjustable supports. In use, the first and second housings at least in part envelop the workpiece such that the independently adjustable supports retain the workpiece within the first and second housings, so as to allow the retained workpiece to be moved. A method of moving a workpiece is also disclosed.