Rotating Fixture Assembly for Gap-Free Blank Shearing and Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fixture assemblies for laser welding face issues with misalignment due to minor variations in blank dimensions, leading to gaps that require additional filler material and increased cycle times, especially when shearing and welding operations necessitate multiple unclamping and repositioning of blanks.
Innovation Solution
A fixture assembly with a rotating frame, vertical and horizontal actuators, and clamps that allow for single clamping during shearing and welding, enabling precise alignment and elimination of gaps without filler material by shearing blanks in overlapping positions and utilizing burr material for smoother welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fixture assemblies use clamps to hold blanks in place, then the blanks are secured during welding, but minor variations in blank dimensions cause misalignment and gaps that require additional filler material and increased cycle time
Solution Approach 1:
The fixture assembly incorporates a moveable block that can be dynamically repositioned relative to the fixed block along the x-axis and y-axis. This dynamic adjustment capability allows the fixture to accommodate dimensional variations in blanks while maintaining precise alignment, eliminating gaps without requiring filler material or additional cycle time for repositioning
Solution Approach 2:
The system changes the positional parameters of the moveable block to optimize alignment. By adjusting the position of the moveable block based on the actual dimensions of the blanks, the fixture maintains reliable alignment accuracy while preventing time losses associated with manual repositioning or filler material application
2Loss of substance
If blanks are sheared prior to welding to provide desired size and shape, then the final component weight is reduced, but rough/burred edges create gaps that are difficult to bridge during laser welding without added filler
Solution Approach 1:
The fixture assembly acts as an intermediary that enables precise positioning of blanks during shearing operations. By securing blanks to both fixed and moveable blocks with controlled alignment, the system ensures that sheared edges remain flush and gap-free, eliminating the need for filler material while maintaining the weight reduction benefits of pre-shearing
Solution Approach 2:
The fixture enables preliminary shearing operations to be performed with precise alignment control. By positioning blanks correctly before shearing using the moveable and fixed blocks, the system produces clean edges that are ready for welding without requiring additional filler material or corrective operations
3Adaptability or versatility
If blanks are unclamped and relocated multiple times during shearing and welding operations, then positioning adjustments can be made, but cycle time increases and operational complexity increases
Solution Approach 1:
The fixture assembly merges the functions of positioning and clamping into a single integrated system. The moveable block can be repositioned while blanks remain clamped, combining positioning adjustment with continuous clamping support. This eliminates the need for separate unclamping and relocating operations, maintaining positioning flexibility while significantly reducing cycle time
4Manufacturing precision
If conventional fixture assemblies require multiple unclamping and repositioning operations, then alignment can be adjusted, but device complexity and operational difficulty increase
Solution Approach 1:
The dynamic moveable block allows alignment adjustments to be made without unclamping operations. The operator can simply reposition the moveable block while the blanks remain securely clamped, maintaining alignment precision while dramatically simplifying the operation and reducing the number of steps required
Data Source
Figure 1
Figure 2~2B
Figure 3
AI summary
A fixture assembly for supporting a plurality of blanks during a shearing and welding operation. The fixture assembly includes a base frame. A rotating frame is rotatably connected to the base frame. A fixed block is fixed to the rotating frame for supporting a first blank. A moveable block is moveably connected to the rotating frame for supporting a second blank. A first clamp is provided for coupling the first blank to the fixed block. A second clamp is provided for coupling the second blank to the moveable block. A vertical actuator is coupled with the rotating frame and configured to move the moveable block in a vertical direction being perpendicular to a plane of the rotating frame for moving the second blank. A horizontal actuator is coupled with the rotating frame and configured to move the moveable block in a horizontal direction.