Shape Memory Fixture Pad for Adaptive Clamping
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Solution Overview
Problem
Current flexible manufacturing systems face challenges in efficiently reconfiguring fixtures to accommodate various workpiece configurations, particularly in mass production scenarios, where traditional modular and conformable fixtures are either too inflexible or too costly, and often risk damaging aesthetically important surfaces during clamping.
Innovation Solution
A reconfigurable fixture device utilizing a shape memory material pad that can selectively conform to different workpiece surfaces, activated by a controller and sensors, allowing for adaptive clamping and support without manual adjustment, suitable for a wide range of workpiece configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional modular fixtures are used, then the fixture can be reconfigured for different part designs, but the reconfiguration time is long and the fixture lacks intrinsic ability to adapt to different sizes and shapes
Solution Approach 1:
The fixture employs dynamically adjustable support elements and clamping mechanisms that can be repositioned and reconfigured during operation. The support blocks can be moved to different locations, and the clamping force can be adjusted, allowing the fixture to adapt to different part sizes and shapes without requiring complete disassembly or lengthy reconfiguration procedures.
Solution Approach 2:
The fixture utilizes adjustable parameters such as support block positions, clamping forces, and locator heights that can be modified to accommodate different part configurations. By changing these parameters rather than the entire fixture structure, rapid adaptation to different part designs is achieved while minimizing reconfiguration time.
2Reliability
If encapsulant fixtures with low melting-point metals are used, then complex parts can be held securely, but the process is costly and time-consuming
Solution Approach 1:
The invention replaces the encapsulant process (which involves melting and solidifying metal) with a mechanical clamping system. The fixture uses mechanically actuated clamps and support blocks that can be adjusted and positioned without requiring thermal processing, thereby eliminating the costly and time-consuming encapsulant manufacturing process while maintaining secure holding capability.
Solution Approach 2:
Instead of using a single encapsulant material to hold the entire complex part, the fixture divides the support and clamping function into multiple discrete mechanical elements (support blocks, clamps, locators) that can be independently adjusted and positioned, providing secure holding without the need for encapsulation.
3Manufacturing precision
If contoured clamp blocks are fabricated by NC machining, then accurate support for specific workpieces is achieved, but multiple clamp blocks are required for multiple workpiece configurations
Solution Approach 1:
The fixture employs universal support blocks and locators that can be repositioned and reconfigured to support multiple different workpiece configurations. Rather than having dedicated contoured clamp blocks for each part type, the same set of standardized support elements serves multiple functions by being adjusted to different positions and orientations, thereby reducing the total number of components needed.
Solution Approach 2:
The support blocks are designed to be dynamically repositionable rather than fixed in specific contoured shapes. This allows the same block to provide accurate support for different workpiece configurations by being moved to appropriate locations, eliminating the need to fabricate multiple specialized clamp blocks through NC machining.
4Ease of operation
If clamps are used on aesthetically important surfaces, then workpieces can be secured during assembly, but the surfaces may be scratched or locally deformed
Solution Approach 1:
The fixture incorporates compliant or flexible clamp blocks that can deform elastically to conform to the workpiece surface without exerting excessive localized pressure. These flexible elements distribute the clamping force over a larger area and can accommodate surface irregularities, preventing scratching and local deformation while maintaining secure clamping on aesthetically important surfaces.
Solution Approach 2:
The clamp blocks are designed with compliant materials or structures that inherently cushion the clamping action before contact with the workpiece surface. This beforehand cushioning prevents direct rigid contact that could cause surface damage, allowing secure clamping while protecting aesthetically important surfaces from scratches and deformation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and damage-free clamping and support of diverse workpieces on both visible and hidden surfaces, reducing the need for multiple fixtures and minimizing production downtime, while maintaining the aesthetic quality of the workpieces.
Implementation Method 1
a reconfigurable pad disposed on the base member, wherein the reconfigurable pad comprises a shape memory material configured to selectively conform to a surface contour of a workpiece
Data Source
AI summary
A reconfigurable fixture device system, including: a base member; a reconfigurable pad disposed on the base member, wherein the reconfigurable pad comprises a shape memory material configured to selectively conform to a surface contour of a workpiece; an activation device in operative communication with the shape memory material; a controller in operable communication with at least one of the reconfigurable pad, the activation device, and the base member; a plurality of sensors for sensing a parameter associated with at least one of the reconfigurable pad, the base member, the fixture device, and the workpiece, wherein the plurality of sensors is in operable communication with the controller; and an actuator in operable communication with the controller and the at least one of the reconfigurable pad, the base member, the fixture device, and the workpiece.