Modular Gage System Using Ball Lock Mechanism for Rapid Reconfiguration
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Solution Overview
Problem
Current gage systems are large, heavy, custom-made, and expensive due to their single-use nature, requiring extensive time and resources for manufacturing, making them inefficient and costly for inspecting and verifying part sizes and tolerances in manufacturing.
Innovation Solution
A modular gage system featuring a base plate with an array of holes and a coordinate system, along with risers and form blocks that can be easily assembled and disassembled, utilizing a ball lock mechanism for secure engagement, allowing for flexible configuration and reusability across different workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If custom-manufactured gages are made for each individual part, then measurement accuracy and suitability for specific parts are improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The gage system is divided into modular components including a base plate with coordinate system, multiple risers of different heights, and interchangeable form blocks. Each component can be independently manufactured and stored, then assembled as needed for specific parts, eliminating the need to manufacture complete custom gages for each part.
Solution Approach 2:
The base plate with coordinate system and array of holes serves as a universal foundation that can accommodate multiple risers and different form blocks. This single base plate can be used to inspect various different parts by reconfiguring the riser and form block arrangement, making the system multi-functional rather than single-use.
2Adaptability or versatility
If custom-manufactured gages are made for each individual part, then suitability for specific part inspection is improved, but manufacturing cost increases
Solution Approach 1:
The gage system is divided into modular components including a base plate with coordinate system, multiple risers of different heights, and interchangeable form blocks. Each component can be independently manufactured and stored, then assembled as needed for specific parts, eliminating the need to manufacture complete custom gages for each part.
Solution Approach 2:
Instead of discarding entire custom gages when production changes, the modular system allows recovery and reuse of the base plate, risers, and form blocks. Components are discarded or reused based on their wear and functionality, not because the specific part inspection requirement changes.
3Device complexity
If entire gage systems are scrapped when parts go out of production, then single-use simplicity is maintained, but resource waste and cost increase
Solution Approach 1:
Instead of discarding entire custom gages when production changes, the modular system allows recovery and reuse of the base plate, risers, and form blocks. Components are discarded or reused based on their wear and functionality, not because the specific part inspection requirement changes.
Solution Approach 2:
The base plate with coordinate system and array of holes serves as a universal foundation that can accommodate multiple risers and different form blocks. This single base plate can be used to inspect various different parts by reconfiguring the riser and form block arrangement, making the system multi-functional rather than single-use.
4Productivity
If modular components are used with ball lock mechanisms, then assembly speed and reusability are improved, but device complexity increases
Solution Approach 1:
The ball lock mechanisms allow risers and form blocks to be quickly assembled and disassembled from the base plate. The engagement structures provide secure locking during use but allow rapid reconfiguration when needed, making the system dynamically adaptable rather than statically fixed.
Data Source
AI summary
A modular gage system includes a base plate having an array of holes and a coordinate system to identify each hole. The modular gage system further includes a plurality of risers and at least one form block. Each riser is assigned to a particular hole and the at least one form block is configured to be positioned atop one or more of the risers. Moreover, each form block is assigned to be located over a particular hole.