Modular Profile Tube Support for Machining Tool Height Adjustment
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Solution Overview
Problem
Existing modular support systems for machining tools in motor vehicle body manufacturing require significant effort to adjust the height and angle accurately, as they rely on complex adjustments of profile tubes and screw elements, which can be cumbersome and imprecise.
Innovation Solution
A modular support system featuring a profile tube with grid holes and a connection part with screw holes, allowing for rough height adjustments via screwing and fine adjustments using compensating plates of varying thicknesses, ensuring precise positioning of machining tools without additional aids or measuring devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a precision steel profile tube with custom-cut length and drilled positioning holes is used, then the machining tool can be positioned accurately in terms of height and angle, but the production effort and complexity increase significantly
Solution Approach 1:
The support system is divided into modular components: a standardized profile tube with grid holes, adjustable connection parts, and interchangeable machining tools. This segmentation allows each component to be standardized and manufactured independently, reducing overall production complexity while maintaining positioning accuracy through the grid hole system.
Solution Approach 2:
The profile tube features a standardized grid hole pattern with specific spacing (e.g., 50mm or 100mm intervals) that provides discrete positioning options. This parameter standardization enables accurate positioning without requiring custom drilling for each application, thereby reducing production effort while maintaining precision.
2Manufacturing precision
If the length of the profile tube and position of fixing holes are adjusted to change height and angle, then the machining tool positioning is accurate, but the adjustment process involves a great deal of effort
Solution Approach 1:
The connection part is designed to be adjustable along the profile tube, allowing the machining tool height and angle to be modified dynamically. The standardized grid hole pattern enables quick repositioning by simply moving the connection part to different holes and securing it with fasteners, making the adjustment process flexible and operator-friendly.
Solution Approach 2:
The profile tube with its standardized grid hole pattern serves multiple functions: it provides structural support, enables height adjustment, allows angle modification, and facilitates tool replacement. This multi-functionality eliminates the need for separate adjustment mechanisms, simplifying the overall adjustment process while maintaining positioning accuracy.
3Ease of operation
If a polygonal profile tube with lateral grid surfaces and rows of holes is used, then the processing tool can be adjusted in height steps, but the adjustment is limited to discrete grid spacing intervals
Solution Approach 1:
The support system incorporates not only vertical height adjustment through grid holes but also angular adjustment capabilities. The connection part can be positioned at different angles relative to the profile tube, and the machining tool can be oriented in multiple directions. This multi-dimensional adjustment capability provides continuous positioning freedom beyond discrete vertical steps.
Data Source
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AI summary
The modular support system comprises a profiled tube (14) fixed to a mounting base (13) via a foot part (12), where the profiled tube is formed with a first hole row from grid holes spaced in a tube longitudinal direction by a first grid spacing, and a connection part (19) associated with a machining tool (16), where the connection part is formed with a second hole row from bolt holes spaced in the tube longitudinal direction by a second grid spacing and is screwed together with a screw element on the profile tube. The screw element is guided with the grid and bolt holes. The modular support system comprises a profiled tube (14) fixed to a mounting base (13) via a foot part (12), where the profiled tube is formed with a first hole row from grid holes spaced in a tube longitudinal direction by a first grid spacing, and a connection part (19) associated with a machining tool (16), where the connection part is formed with a second hole row from bolt holes spaced in the tube longitudinal direction by a second grid spacing and is screwed together with a screw element on the profile tube. The screw element is guided with the grid and bolt holes. The connecting part is adjustable in a height by a step height for the coarse adjustment of a heightwise position of the machining tool spaced from the mounting base. A set of compensating plate of different material thickness is provided for the fine adjustment of the height position of the machining tool of the support system. The first grid spacing of the hole row of the profile tube is twice the second height distance of the hole row of the connecting part. The compensating plate has thickness that is less than the grid spaces. The connection part for the correct positioning of the profile tube comprises a centering element such as a centering pin that is guided with a hole tolerance, by the grid holes, reduced in comparison to the screw element. The profile tube is formed with grid surfaces in a polygon-shaped manner, where the grid surfaces merge into one another at longitudinal edges. The connection part for securing the position in a radial direction comprises the centering surfaces, which are contour-adapted to a tubular shape of the profile tube, where a central bearing surface carries the centering element. The connection part further comprises fastening points spaced in the tube longitudinal direction. The centering element such as a sword pin is arranged in the radial direction of the profile tube having a movement game in the grid hole, and is arranged for securing the position in the tube longitudinal direction with a play-free reduced in comparison to a circumferential direction. The connection part and/or the foot part comprises two torque supports that are diametrically opposite to the side in contact with the profile tube.