Rotating Welding Fixture Assembly for Single-Clamp Blank Alignment
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Solution Overview
Problem
Conventional fixture assemblies for laser welding often result in misalignment due to minor variations in blank dimensions, requiring additional materials and increased time and costs, especially since blanks need to be unclamped and repositioned multiple times during shearing and welding operations.
Innovation Solution
A fixture assembly with a rotating frame, vertical, and horizontal actuators, and magnetic blocks that allow for single clamping and precise alignment of blanks during shearing and welding, enabling seamless transition without manual repositioning, allowing for flush unions and reduced material usage.
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 cannot be laser welded without additional filler wire
Solution Approach 1:
The fixture assembly incorporates movable blocks with adjustable positions along the beam, allowing dynamic repositioning to accommodate dimensional variations in blanks. The blocks can be moved horizontally and vertically to maintain precise alignment between blanks during welding, eliminating gaps and the need for filler wire
Solution Approach 2:
The system allows changing the positional parameters of the movable blocks to adapt to different blank dimensions. By adjusting the location of support blocks, the fixture can compensate for dimensional variations and maintain optimal alignment for laser welding without requiring filler materials
2Weight of moving object
If blanks are sheared to provide desired size and shape, then the final component weight is reduced, but the rough/burred edge from shearing creates gaps between blanks that are difficult to bridge during laser welding
Solution Approach 1:
The fixture assembly performs preliminary positioning and alignment of blanks before welding. By pre-positioning the movable blocks to account for sheared edges, the system compensates for rough edges created during shearing, ensuring proper alignment and gap closure before the welding process begins
Solution Approach 2:
The movable blocks act as intermediaries between the sheared blanks and the welding process. These blocks provide stable support and precise positioning that compensates for the poor edge quality from shearing, enabling successful laser welding of blanks with rough edges
3Manufacturing precision
If blanks are unclamped and relocated multiple times during shearing and welding operations, then precise positioning can be achieved, but the cycle time and operational complexity increase significantly
Solution Approach 1:
The fixture assembly combines multiple positioning and support functions into a single integrated system. The movable blocks can simultaneously provide support, positioning, and alignment functions, eliminating the need for multiple separate operations of unclamping and relocating blanks
Solution Approach 2:
The movable blocks serve multiple functions: supporting blanks, providing precise positioning, enabling alignment adjustments, and maintaining clamping pressure. This multi-functionality replaces what would otherwise require multiple separate operations, reducing cycle time while maintaining positioning accuracy
Data Source
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.