Self-Aligning Extension Block Assembly for Workpiece Edge Positioning
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Solution Overview
Problem
Existing work carriers struggle to efficiently and securely support and align work objects, such as vehicle doors, during assembly processes, particularly when transitioning between different assembly stations, leading to potential misalignment and instability.
Innovation Solution
A self-aligning extension block assembly is integrated into the work carrier, comprising a perch bracket and a locator bracket that pivot about different axes, with movable protrusions and openings to control pivot degrees, allowing the block to self-align with the work object's edge, ensuring secure support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed clamp assembly is used to support the work object, then the structure is simple and stable, but it cannot adapt to different assembly configurations and may cause misalignment
Solution Approach 1:
The clamp assembly incorporates movable components including a slider assembly that can translate along the frame and extension block assemblies with pivotable brackets. These dynamic elements allow the clamp to adjust its position and orientation to accommodate different work object sizes and assembly configurations, resolving the contradiction between adaptability and structural simplicity.
Solution Approach 2:
The clamp assembly is divided into multiple independent functional segments: a base assembly, a slider assembly, and extension block assemblies. Each segment can move or adjust independently, enabling the overall structure to adapt to various configurations while maintaining manageable complexity through modular design.
2Manufacturing precision
If rigid support structures are used, then alignment precision is maintained, but the system cannot self-adjust to accommodate variations in work object positioning
Solution Approach 1:
The extension block assemblies are designed with pivotable brackets that automatically self-align with the work object edge through controlled movement. The locator bracket pivots about a first axis and the block pivots about a second axis, allowing the system to self-adjust to variations in work object positioning without requiring manual intervention, thus achieving both precision and ease of operation.
Solution Approach 2:
The clamp assembly utilizes controlled changes in positional parameters through the slider assembly's linear movement and the pivot brackets' rotational movement. These parameter changes enable the rigid support structures to adapt their configuration dynamically, maintaining alignment precision while accommodating positioning variations automatically.
3Productivity
If the clamp assembly is designed for quick adjustment, then productivity is improved, but the stability and secure engagement of the work object may be compromised
Solution Approach 1:
The slider assembly enables quick linear adjustment of the extension blocks along the frame, allowing rapid repositioning for different work objects. Once positioned, the pivotable brackets lock into place through their pivot mechanisms, providing stable and secure engagement. This dynamic design achieves both quick adjustment for productivity and secure engagement for reliability.
Data Source
AI summary
A work carrier assembly includes a frame for supporting a work object, and a clamp assembly fixed to the frame, which includes an extension block assembly including a perch bracket and a locator bracket. The locator bracket is pivotably engaged with the perch bracket, and a block is pivotably engaged with the locator bracket.