Screw-On Mandrel Geometry for Precise Multi-Component Alignment
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Solution Overview
Problem
Conventional mandrels used for aligning components in industrial steel construction often result in residual offsets and pose safety risks due to splintering when trying to remove them, and are unsuitable for connecting three or more components accurately.
Innovation Solution
A screw-on mandrel with a cylindrical shaft and a longitudinal cone, featuring an internal thread and a stop surface, which allows for precise alignment and easy removal by being unscrewed from the screw after alignment, enabling the use of additional screws to secure components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the impact mandrel is driven in only to the area of the cone, then the mandrel can be inserted easily, but there will be a residual offset between the components and they will not be precisely aligned
Solution Approach 1:
The mandrel is divided into two distinct functional sections: a conical insertion section for easy alignment and insertion, and a cylindrical working section that extends beyond the cone to provide the necessary impact depth for precise hole alignment. This segmentation allows each section to optimize its specific function without compromising the other.
Solution Approach 2:
The conical section performs the preliminary action of guiding and pre-aligning the mandrel with the hole opening, making insertion easy. The cylindrical section then completes the alignment by providing sufficient impact depth to precisely align the screw holes before the actual screwing operation begins.
2Manufacturing precision
If the impact mandrel is driven in beyond the cone, then the hole alignment can be precise, but the mandrel can only be removed by striking the hardened tip which poses a considerable risk of accidents due to chipping
Solution Approach 1:
The hazardous hardened tip is extracted and replaced with a cylindrical section that has sufficient strength for alignment but can be safely removed by unscrewing. The cylindrical section maintains the necessary impact depth for precise alignment while eliminating the chipping risk associated with striking a hardened conical tip.
Solution Approach 2:
The mandrel is designed as a disposable or single-use tool where the cylindrical section can be easily removed by unscrewing after alignment. This eliminates the need for dangerous removal methods and allows the mandrel to be discarded or replaced without safety concerns, similar to a disposable alignment tool.
3Productivity
If conventional mandrels are used for connecting three or more components, then the assembly process can proceed, but proper alignment of the parts to each other cannot be achieved
Solution Approach 1:
The mandrel is designed with a cylindrical section that can engage with multiple components simultaneously, allowing it to serve as a universal alignment tool for connecting three or more components. The cylindrical geometry provides reference surfaces that ensure proper alignment across multiple parts in a single operation.
Solution Approach 2:
The mandrel extends in the axial dimension beyond the conical section, providing a cylindrical working length that can interact with multiple components stacked or arranged in sequence. This dimensional extension allows the single mandrel to align multiple screw holes across several components simultaneously, rather than requiring separate alignment operations for each component pair.
Data Source
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AI summary
The invention relates to a screw-on mandrel (1) for aligning components to be joined together, comprising a shaft extending over a first longitudinal region, which is essentially cylindrical, and a cone (3) adjoining the shaft and extending over a second longitudinal region, wherein the shaft (2) has an interior space (2.3) which is open towards an end face (2.2) of the shaft (2) opposite the cone (3). The interior space (2.1) has an internal thread (2.3) extending from the end face (2.2) of the shaft (2) and a stop surface (2.4) at the bottom of the interior space (2.1), the stop surface (2.4) being formed in the form of a bulge towards the end face (2.2). The invention further relates to a method for aligning components using at least one screw-on mandrel (1) according to the invention.