Phase Change Material Part Holding Fixture
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Solution Overview
Problem
Current manufacturing fixtures for holding parts during operations, such as machining, are either costly, complex, or inefficient due to the need for multiple fixtures for different part shapes, and often require extensive setup and maintenance, especially for large or varied parts.
Innovation Solution
An adjustable part holding fixture system utilizing a phase change material within a container, which can be converted between a non-rigid and rigid state by a control device, allowing for adaptable and secure holding of parts of varying shapes without the need for multiple fixtures, featuring a base assembly with part holding assemblies that can be easily reconfigured and securely attach to the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid fixtures are used to hold parts during manufacturing, then the part can be securely held, but multiple fixtures are required for different part classes resulting in increased manufacturing, maintenance, and storage costs
Solution Approach 1:
The patent applies parameter changes by utilizing a phase change material that transitions between solid and liquid states. When the material is in its liquid state, it can be easily poured into the fixture body and removed. When frozen into a solid state, it provides rigid support and secure holding for parts. This phase change allows a single fixture to adapt to different part classes without requiring multiple dedicated fixtures, thereby resolving the contradiction between secure holding and adaptability.
Solution Approach 2:
The patent employs a composite material system consisting of a phase change material combined with a flexible membrane. The phase change material provides the necessary structural support when frozen, while the flexible membrane allows the fixture to conform to different part geometries. This composite approach enables the fixture to maintain reliability across various part types while improving adaptability.
2Adaptability or versatility
If freeze chucks are used to adapt to different part shapes, then adaptability is improved, but the freezing time significantly increases for large parts resulting in increased manufacturing time
Solution Approach 1:
The patent divides the fixture into a reusable fixture body and a replaceable phase change material component. The phase change material can be independently frozen and replaced without affecting the fixture body. This segmentation allows for faster cycle times because only the material needs to be frozen, not the entire fixture assembly, thereby improving productivity while maintaining adaptability.
Solution Approach 2:
The patent implements preliminary action by pre-freezing the phase change material in the fixture body before part installation. This allows the material to be ready in a controlled state, and the part can be quickly transferred into position. The flexible membrane is also pre-positioned to conform to expected part geometries, reducing setup time and improving overall manufacturing efficiency.
3Adaptability or versatility
If flexible fixtures with multiple independent actuators are used to fit part shapes, then adaptability is improved, but the system becomes expensive, complex, and requires increased floor space
Solution Approach 1:
The patent replaces complex mechanical actuator systems with a phase change material-based adaptation mechanism. Instead of using multiple independent actuators to adjust fixture elements, the phase change material naturally conforms to part geometries through its phase transition properties. This substitution dramatically reduces device complexity while maintaining adaptability to different part shapes.
Solution Approach 2:
The phase change material performs the adaptation function autonomously through its inherent phase change properties. When transitioning from liquid to solid state, the material automatically conforms to the part geometry without requiring external actuation or control systems. This self-service mechanism eliminates the need for complex mechanical adjustment systems, reducing both complexity and cost while preserving adaptability.
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 system provides a cost-effective, reliable, and compact solution that minimizes setup time and storage needs, reduces maintenance costs, and ensures secure part holding during manufacturing processes, adapting to different part shapes without complex motor control or extensive setup.
Implementation Method 1
a phase change material contained within the container... configured to convert the phase change material between a non-rigid state and a rigid state
Data Source
AI summary
There is provided an adjustable part holding fixture, system and method. The fixture has a base assembly with a container and a phase change material contained within the container. The fixture has a control device to convert the phase change material between a non-rigid state and a rigid state. The fixture has a plurality of part holding assemblies, each having a base anchoring portion for insertion into and positioning in the phase change material, and a part attachment portion configured to releasably attach to a surface of a part being held by the fixture. The phase change material in the non-rigid state allows for positioning of the base anchoring portion and adjusting to the part being held, and the phase change material in the rigid state holds the base anchoring portion in a desired position and holds the part in place during one or more processes performed on the part.