Clamps and methods of forming clamps
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Solution Overview
Problem
Laser projection alignment systems require precise calibration, which can be disrupted by foreign objects during the assembly of large assemblies like aircraft, leading to inefficiencies and potential damage from disassembling already assembled components to retrieve misplaced tools or objects.
Innovation Solution
The development of clamps with monolithic members that are coupled together using additive manufacturing, preventing separation without alteration, to securely position laser projection alignment targets and minimize foreign object damage by ensuring components remain in place during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional clamps with separable components are used, then ease of assembly and disassembly is improved, but foreign objects can be lost or trapped in the assembly, causing damage and requiring disassembly to retrieve
Solution Approach 1:
The clamp integrates multiple components into a single monolithic structure formed by additive manufacturing. The clamp body, positioning features, and fastening elements are all part of one continuous piece, eliminating separate components that could be lost or trapped during assembly operations.
2Ease of manufacture
If traditional multi-component clamps are used, then ease of manufacture is improved, but device complexity increases with multiple parts that can be separated
Solution Approach 1:
Multiple clamp components are merged into a single monolithic structure through additive manufacturing. This integration reduces the number of separate parts and assembly steps while the additive manufacturing process handles the complexity of creating integrated features that would be difficult with traditional manufacturing methods.
Solution Approach 2:
The manufacturing approach changes from traditional subtractive or assembly-based methods to additive manufacturing. This parameter change in the manufacturing process enables the creation of complex integrated geometries that combine multiple functions in a single component, resolving the contradiction between manufacturing ease and device complexity.
3Productivity
If clamps with separable components are used, then productivity is improved through quick assembly, but loss of time occurs when disassembly is required to retrieve foreign objects
Solution Approach 1:
The monolithic clamp structure eliminates separate components that could be lost during assembly. By integrating all functional elements into one piece, the clamp maintains quick assembly capabilities while preventing the scenario where disassembly is needed to retrieve foreign objects, thus avoiding time loss.
Solution Approach 2:
The clamp design proactively prevents foreign object loss by integrating all necessary components into a single piece that cannot separate. This preliminary design decision prevents the harmful scenario of lost components before it can occur, eliminating the need for time-consuming disassembly operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The clamps effectively prevent foreign object damage and inefficiencies by maintaining the precise positioning of components, allowing for successful calibration of laser projection alignment systems and reducing the need for disassembly, thus enhancing assembly efficiency and reducing resource expenditure.
Implementation Method 1
The monolithic members of clamps according to the present disclosure may be formed utilizing an additive manufacturing method so that they are restricted from being decoupled from each other
Data Source
AI summary
Apparatuses include first and second monolithic members that are coupled together, that are configured to move relative to each other, and that are configured so that they cannot be decoupled from each other without destruction of one or both of the two monolithic members. Apparatuses further include a third monolithic member configured to be selectively coupled to at least one of the first monolithic member and the second monolithic member. Methods of forming and using such apparatuses also are disclosed. Some monolithic members are formed utilizing an additive manufacturing process so that they are restricted from being decoupled from each other. Some apparatuses define clamps. Some clamps are used to precisely align laser projection alignment targets for use with laser projection alignment systems.