Rest Pad Force Sensor Closed-Loop Feedback Manufacturing Fixture
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Solution Overview
Problem
Conventional manufacturing fixtures require manual intervention to ensure proper contact force and positioning of workpieces on rest pads, leading to potential misalignment, waste, and damage during machining and assembly operations, as they lack dynamic feedback and force adjustment capabilities.
Innovation Solution
A manufacturing fixture with integrated rest pad force sensors and a closed-loop feedback system that monitors and adjusts contact forces in real-time, using sensors to detect deviations from predetermined thresholds and alert operators or automatically adjust clamping forces to maintain proper contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual monitoring with filler gauges is used to check contact force, then operators can detect gaps between workpiece and rest pads, but the process requires continuous manual intervention and cannot dynamically adjust clamping forces
Solution Approach 1:
The patent replaces manual mechanical measurement tools (filler gauges) with electronic force sensors that automatically detect contact forces between the workpiece and rest pads. This substitution enables continuous automated monitoring and allows the control system to dynamically adjust clamping forces without manual intervention, resolving the contradiction between measurement capability and automation level.
Solution Approach 2:
The patent implements a closed-loop feedback system where force sensors continuously monitor contact forces and transmit data to a control system. The control system compares measured forces against target values and automatically adjusts clamping device forces to maintain proper contact. This feedback mechanism eliminates the need for manual monitoring while enabling dynamic force adjustment, simultaneously improving measurement precision and automation extent.
2Manufacturing precision
If conventional fixtures without force monitoring are used, then the device complexity is lower, but workpiece positioning accuracy and stability cannot be ensured
Solution Approach 1:
The patent integrates force sensing capabilities into the existing rest pad structure, allowing the same component to serve both as a support surface and a measurement device. The control system also performs multiple functions: monitoring forces, comparing against targets, and actuating adjustments. This multi-functionality approach improves positioning accuracy without proportionally increasing overall system complexity.
Solution Approach 2:
The fixture system automatically monitors and adjusts its own clamping forces through the integrated sensors and control system, eliminating the need for external manual verification and adjustment. The system self-corrects positioning issues by dynamically adjusting clamping forces based on real-time feedback, thereby ensuring manufacturing precision while keeping the added complexity minimal and self-contained.
3Stability of the object's composition
If dynamic feedback and automatic adjustment systems are implemented, then workpiece positioning stability is improved, but the device complexity and initial cost increase
Solution Approach 1:
The patent implements a closed-loop feedback system where force sensors continuously monitor contact forces between the workpiece and rest pads. The control system receives this data, compares it against target force values, and automatically adjusts clamping device forces to maintain proper contact. This feedback mechanism ensures workpiece positioning stability by dynamically compensating for any deviations, while the modular architecture keeps the added complexity manageable.
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
This solution ensures accurate and stable workpiece positioning, reducing the risk of misalignment, waste, and damage by providing continuous, dynamic feedback and force control, thereby improving manufacturing efficiency and safety.
Implementation Method 1
a sensor associated with the at least one rest pad and configured to sense a force exerted on the rest pad by the component during manufacturing
Data Source
AI summary
A manufacturing fixture process, and associated device for practicing the disclosed process, includes supporting a component during manufacturing by at least one rest pad, and sensing and transmitting a force signal exerted on the rest pad by the component during manufacturing by at least one sensor associated with the at least one rest pad. The process further includes clamping the component onto the rest pad by a clamping component configured to rigidly hold the component, receiving and monitoring the force exerted on the rest pad by a force monitoring system configured to receive and monitor the signal indicating the force exerted on the rest pad, as well as determine whether the force exerted on the rest pad is within a predetermined range, exceeds the predetermined range, and/or is below the predetermined range, and outputting the force exerted on the rest pad with an output device.