Automatic Support Fixture Generation for Precise Part Retention
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Solution Overview
Problem
Conventional support device generation methods for high-mix, low-volume manufacturing are inefficient, leading to low resolution, insufficient work holding strength, part over- or under-constraint, tool interference, and visual defects due to the difficulty and cost of custom fixture manufacture.
Innovation Solution
A method for automatic support device generation that receives a virtual part model, determines retention direction and rotation, and constructs a custom support device to optimize work holding, using a computing system to expedite manufacturing, reduce errors, and minimize manufacturing time by generating an optimal support device for specific part and machine parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional support device generation methods are used for high-mix, low-volume manufacturing, then manufacturing flexibility is maintained, but manufacturing precision and work holding strength deteriorate due to low resolution and insufficient customization
Solution Approach 1:
The system creates a virtual copy of the support device in a digital environment, allowing for precise customization and optimization without the complexity of direct physical manufacturing. The virtual model can be iteratively refined and tested before physical production, achieving high precision while reducing manufacturing complexity.
Solution Approach 2:
The system performs preliminary virtual prototyping and validation of support devices before actual manufacturing. By simulating and optimizing the support device design in a virtual environment first, the system ensures high precision and work holding strength while minimizing the complexity of the physical manufacturing process.
2Strength
If custom support devices are manufactured for each part, then work holding strength improves, but manufacturing time and cost increase due to difficulty and cost of custom fixture manufacture
Solution Approach 1:
The system uses virtual modeling to create and validate support device designs digitally before physical manufacturing. This allows for rapid iteration and optimization of custom support devices, maintaining high work holding strength while significantly reducing the time required for manufacturing through automated virtual prototyping and validation.
Solution Approach 2:
The system replaces manual mechanical design and manufacturing processes with automated computer-based virtual modeling and validation. This substitution enables rapid customization of support devices with high work holding strength while minimizing manufacturing time through automated optimization algorithms.
3Manufacturing precision
If conventional support devices are used, then manufacturing simplicity is maintained, but manufacturing precision deteriorates due to part over- or under-constraint and visual defects
Solution Approach 1:
The system creates virtual models of support devices that can be precisely configured to match specific part geometries and manufacturing requirements. This virtual copying approach enables accurate part constraint and surface quality control while the automated system handles the complexity, making implementation easier despite the high precision requirements.
Solution Approach 2:
The system performs preliminary virtual validation to ensure optimal part constraint and surface quality before physical manufacturing. By pre-configuring and validating the support device design in a virtual environment, the system achieves high manufacturing precision while the automated nature of the process keeps implementation complexity manageable.
4Productivity
If manual support device design processes are used, then flexibility in customization is maintained, but productivity decreases due to inefficient generation methods
Solution Approach 1:
The system replaces manual support device design processes with automated computer-based virtual modeling and optimization. This substitution dramatically improves productivity by enabling rapid generation and validation of custom support devices, while the high level of automation becomes the enabler rather than a barrier to customization flexibility.
Solution Approach 2:
The system uses automated virtual copying and modeling to rapidly generate custom support device designs. This automated approach to creating virtual models significantly increases productivity compared to manual methods, while the flexibility to customize each virtual model to specific requirements is maintained through parametric design capabilities.
Data Source
AI summary
The automatic support device generation method includes: receiving a virtual part; determining a retention direction for the virtual part; determining a retention rotation for the virtual part; and constructing a support device based on the part, the retention rotation, and the retention direction.