Multi-Axis Alignment Jig for Precise Heavy Unit Assembly
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Solution Overview
Problem
In heavy engineering applications, aligning large and heavy units for assembly is often time-consuming and hazardous due to the ad-hoc nature of existing jig arrangements, which can result in inadequate alignment and increased rework, especially when conventional cranes are not available.
Innovation Solution
An alignment system comprising a movable alignment jig supported by a track system, with independent actuation units allowing precise positioning and orientation of loads along multiple axes, enabling quick and safe alignment without modifying the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ad-hoc jig arrangements are used for alignment, then the system can be implemented without specialized equipment, but the alignment precision and safety are inadequate
Solution Approach 1:
The alignment jig is divided into multiple independent base units, each with its own actuation system. This segmentation allows each unit to be precisely controlled independently while maintaining overall system adaptability to different alignment scenarios.
Solution Approach 2:
The base units are made movable relative to one another through actuation systems, transforming the static ad-hoc jig into a dynamic system that can adapt its configuration while maintaining precise control over alignment parameters.
2Device complexity
If manual jacking and hydraulic pulling are used, then the alignment process can be performed with simple equipment, but the process is time-consuming and labor-intensive
Solution Approach 1:
Manual jacking and hydraulic pulling operations are replaced with automated actuation systems integrated into the base units. This substitution maintains relatively simple equipment architecture while dramatically increasing alignment speed and reducing manual labor requirements.
Solution Approach 2:
The base units are equipped with self-contained actuation systems that automatically perform positioning operations. The system serves itself by integrating the actuation mechanisms directly into the alignment units, eliminating the need for separate manual or hydraulic operations.
3Weight of moving object
If conventional cranes are used for positioning, then heavy units can be lifted and positioned, but the equipment cannot be deployed in environments without sufficient crane capacity
Solution Approach 1:
The heavy load is distributed across multiple independent base units, each capable of handling a portion of the total weight. This segmentation allows the system to handle heavy objects without requiring a single large-capacity crane, enabling deployment in environments with limited lifting infrastructure.
Solution Approach 2:
The base units are designed as multi-functional elements that can support, position, and orient loads without requiring specialized heavy-lift cranes. This universal design allows the system to operate in diverse environments including those without conventional crane infrastructure.
4Manufacturing precision
If specialized rail systems are installed for unit alignment, then precise alignment can be achieved, but the substrate requires modification which increases cost and reduces flexibility
Solution Approach 1:
The alignment jig acts as an intermediary device between the substrate and the units to be aligned. Instead of modifying the substrate with permanent rail installations, the jig provides a portable, non-invasive interface that achieves precise alignment without requiring substrate modification.
Solution Approach 2:
The base units are designed to be movable relative to one another and to the jig structure, providing dynamic adjustment capability that achieves precise alignment without requiring fixed rail installations on the substrate.
Data Source
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AI summary
An alignment jig (10) configured to support and orient a load (500). The alignment jig (10) may form part of an alignment system (300). The alignment jig (10) comprises a first base unit (100) configured to carry a first support unit (200), the first support unit (200) being configured to support the load (500) and to space the first base unit (100) apart from the load (500). The first support unit (200) is moveable relative to the first base unit (100). The first base unit (100) comprises a first base unit actuation system (110) operable to act on the first support unit (200) along a first base unit operational axis X1. The first support unit (200) comprises a first support unit actuation system (210) operable to act on the load (500) along a first support unit operational axis Y1.