Rotating Collar Flange Welding Fixture for Precise Beam Mount Assembly
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Solution Overview
Problem
Existing manufacturing processes for full moment collar beam mounts face challenges in achieving precise positioning and welding of beam connection components, leading to potential deviations from specifications due to imprecisions in tolerances along the length of building frames.
Innovation Solution
A collar flange assembly welding fixture is developed, comprising a stand with circumferential bearings, a circular mount structure, and a support assembly that includes collar corner simulators and a plate structure with a central opening for access from both sides, allowing precise positioning and rotation for improved welding access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding fixtures are used for collar flange assembly, then welding can be performed, but precise positioning and welding access are limited, leading to deviations from specifications
Solution Approach 1:
The fixture incorporates a rotatable circular mount structure that allows the collar flange assembly to be rotated to different angular positions. This dynamic capability enables welders to access welding positions from multiple angles while the fixture maintains precise positioning through its bearing-supported rotation mechanism and positioning features
Solution Approach 2:
The fixture adds a rotational dimension to the welding process by allowing the assembly to be rotated around a vertical axis. This creates multiple accessible welding approaches (front, back, left, right sides) that were not simultaneously accessible in traditional fixed fixtures, improving welding access without sacrificing positioning precision
2Manufacturing precision
If components are securely supported in precise spatial configuration, then welding precision is improved, but welding access becomes difficult
Solution Approach 1:
The fixture separates the positioning function (provided by the collar corner simulators and positioning features) from the access function (provided by the rotatable circular mount). This segmentation allows precise positioning to be maintained while the rotation capability provides unrestricted welding access from multiple directions
Solution Approach 2:
The circular mount structure acts as an intermediary between the fixed positioning elements and the welding operation. It allows the assembly to be precisely positioned and then rotated to bring different welding areas into optimal access positions for welders
3Productivity
If multiple collar connections are manufactured along the building frame length, then the structure is complete, but tolerances accumulate and cause overall deviation
Solution Approach 1:
The fixture incorporates collar corner simulators that replicate the actual collar geometry and positioning requirements. This self-service approach ensures that each collar flange assembly is manufactured to precise specifications without requiring additional measurement or adjustment steps, maintaining consistency across multiple productions
Data Source
AI summary
A collar flange assembly welding fixture is disclosed, including a stand, a circular mount structure, and a support assembly which are configured to provide access to a front side and a back side of a collar flange assembly held by the support assembly. The stand has a plurality of circumferential bearings equidistant from an axis of rotation, the circular mount structure is rotatably supported by the circumferential bearings, and the support assembly is configured for mounting on the circular mount structure.