Modular Gap-Setting Elements for Precision Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Establishing and maintaining precise gap dimensions between components in structures and machines is challenging due to the tedious and time-consuming nature of current methods, such as using rulers, gauges, and shims, especially in complex geometries, which often results in inadequate or non-uniform gaps affecting quality, durability, and functionality.
Innovation Solution
A set of gap-establishing elements with defined and labeled thicknesses, configured to be stacked or combined using adhesives, interlocking parts, or magnets, allowing for rapid visualization and adjustment of gap dimensions, including color-coding and machine-readable codes for easy identification and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measurement tools (rulers, gauges, shims) are used to establish gap dimensions, then measurement capability is provided, but the process becomes tedious and time-consuming
Solution Approach 1:
The gap dimension establishment tool is segmented into multiple modular components (first component with first gap dimension, second component with second gap dimension, etc.) that can be independently selected and combined. This segmentation allows rapid configuration of appropriate gap dimensions without requiring time-consuming measurements with traditional tools.
Solution Approach 2:
The gap dimensions are pre-determined and built into the modular components during manufacturing. Instead of measuring and calculating gap dimensions during assembly, the components are designed with predetermined gap dimensions that are established in advance, eliminating the need for time-consuming on-site measurements.
2Productivity
If visual estimates are used to establish gap dimensions, then the process is simple and quick, but measurement precision and uniformity deteriorate
Solution Approach 1:
By dividing the gap establishment into discrete modular components with predetermined dimensions, the system maintains precision while enabling quick selection and assembly. Each component represents a specific gap dimension, allowing rapid selection without visual estimation.
Solution Approach 2:
The system provides a set of components with varying predetermined gap dimensions (different parameters). By selecting from this range of predetermined parameters, the system achieves both precision (through exact predetermined dimensions) and productivity (through rapid selection from available options).
3Reliability
If shims of pre-determined dimensions are used to establish gaps, then gap support is provided, but adjustability is limited requiring multiple shim types
Solution Approach 1:
The modular components are designed with standardized interfaces and configurations that allow a single system to handle multiple gap dimension requirements. The components can be selectively combined in different arrangements to achieve various gap dimensions, providing universal applicability across different assembly scenarios without requiring entirely different tools for each gap size.
4Device complexity
If multiple surfaces are combined in three-dimensional space, then complex structures are achieved, but visualization and measurement of all gap dimensions simultaneously becomes difficult
Solution Approach 1:
The complex three-dimensional assembly is broken down into discrete modular components, each responsible for establishing a specific gap dimension. This segmentation allows each component to be independently visualized and positioned, making it easier to manage and verify multiple gap dimensions in complex structures compared to attempting to measure all gaps simultaneously with traditional tools.
Data Source
AI summary
Methods, devices, and kits for measuring and establishing a gap between two surfaces are disclosed, which include and involve the use of a plurality of gap-establishing elements. Each gap-establishing element consists of a three-dimensional object having a defined and consistent thickness across an area that spans at least a partial length of the three-dimensional object. In addition, each gap-establishing element is labeled with a number that is correlated with the defined and consistent thickness that applies to such gap-establishing element. The plurality of gap-establishing elements are configured to be stacked upon or combined with each other. Such gap-establishing elements are useful for measuring and establishing gap dimensions that are included within various structures and/or machines (including simple and complex machines).