Monolithic Clamp Assembly for Laser Target Alignment
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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 resource wastage due to the need for disassembly to retrieve misplaced tools or components.
Innovation Solution
The development of clamps with monolithic members that are coupled together via 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 multi-component clamps are used during assembly, then ease of assembly is improved, but foreign object damage risk increases due to loose components becoming hidden or misplaced
Solution Approach 1:
The clamp combines multiple functional components (clamping jaws, positioning mechanisms, and fastening elements) into a single integrated monolithic member. This merging eliminates loose components that could become foreign objects, while maintaining all necessary clamping and positioning functions through internal geometric features and integrated mechanisms.
Solution Approach 2:
While the clamp itself is monolithic, the invention segments the clamping function into multiple contact points and zones along the length of the clamp, allowing different sections to engage with different parts of the workpiece. This provides effective clamping without requiring multiple separate components.
2Adaptability or versatility
If traditional multi-component clamps are used, then adaptability to different assembly configurations is improved, but loss of time increases due to disassembly required to retrieve dropped components
Solution Approach 1:
By integrating all clamp components into a single monolithic unit, the invention eliminates the need to disassemble multiple parts to retrieve dropped components. The entire clamp can be removed as one piece, significantly reducing recovery time if the clamp is dropped or misplaced during assembly operations.
3Manufacturing precision
If additive manufacturing is used to form monolithic members, then manufacturing precision is improved, but device complexity increases due to the integration of multiple functions in one component
Solution Approach 1:
The invention utilizes additive manufacturing parameters and processes to create complex monolithic geometries that would be difficult or impossible to achieve with traditional manufacturing. The additive process allows for precise control of internal structures, cooling channels, and external features within a single continuous build, achieving high manufacturing precision despite geometric complexity.
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.