Reconfigurable Assembly Fixture Alignment Pins
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Solution Overview
Problem
The construction and maintenance of complex assemblies requiring high precision alignment are challenging due to existing methods and equipment that often necessitate multiple rework activities, as initial assemblies do not meet print specifications, especially with cast elements that have variations, leading to issues with alignment and fit.
Innovation Solution
A reconfigurable assembling and alignment apparatus comprising a base plate and back plate with alignment pins, adjustable compression mechanisms, and tensioners that allow for precise alignment and adjustment of multiple elements, enabling initial assembly, measurement, and reassembly while reducing reconfiguration time and effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cast elements are used for assembly, then manufacturing cost is reduced, but alignment precision deteriorates due to variations in body elements
Solution Approach 1:
Alignment pins are introduced as intermediary elements between the cast components and the assembly fixture. These pins serve as mediators that compensate for the dimensional variations inherent in cast elements, enabling precise alignment to be achieved despite the lower precision of the cast components themselves. The alignment pins translate the imprecise cast surfaces into precise alignment references.
Solution Approach 2:
The invention changes the reference parameter for alignment from the cast surfaces themselves to dedicated alignment pins. By shifting the alignment reference from the variable cast surfaces to precision-manufactured pins, the system maintains the cost benefits of casting while achieving the precision required for proper assembly alignment.
2Manufacturing precision
If multiple rework activities are performed to achieve alignment, then alignment precision is improved, but time consumption and cost increase
Solution Approach 1:
The alignment pins are pre-installed in the assembly fixture before the cast components are positioned. This preliminary action establishes the precise alignment reference in advance, allowing components to be directly positioned against the pins without requiring iterative rework. The alignment geometry is prepared beforehand, eliminating the need for repeated measurement and adjustment cycles.
3Manufacturing precision
If a dedicated assembly apparatus is used for each multi-element assembly type, then alignment precision is improved, but device complexity and reconfiguration time increase
Solution Approach 1:
The assembly fixture is designed with universal alignment pin locations and adjustable positioning mechanisms that can accommodate multiple types of multi-element assemblies. Rather than requiring dedicated fixtures for each assembly type, the same fixture can be reconfigured by adjusting the position of alignment pins and modifying the support structures, enabling one fixture to serve multiple assembly types while maintaining precise alignment for each.
Data Source
AI summary
Systems and methods for assembling different multi-element items with different specifications using a reconfigurable apparatus are provided. One embodiment includes a base plate, a back plate coupled to the base plate in a predetermined angle relationship. The exemplary back plate comprises a plurality of alignment pins adapted to engage with alignment locations of multiple element assembly items. The exemplary base plate and alignment mounting structures couple to end cap parts disposed on opposing ends of the multiple element assembly items holding the items together. A clamping mechanism maintains/releases pressure on the multiple element assembly items against the back plate. The back plate holds alignment pins in a first back plate location in a first orientation for one type of multiple element assembly items and hold the alignment pins in a second location when the back plate is in a second orientation for a different type of multiple element assembly items.