Synchronous Frame Assembly Machine with Rotary Clamps
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Solution Overview
Problem
Existing frame-clamping devices struggle to efficiently assemble large frames, as they require manual intervention to achieve squareness and right angles, and often lack the necessary support and workspace for larger frames, leading to issues with flatness and stability.
Innovation Solution
A frame-clamping machine with extension wings and synchronous motion of miter clamps that securely fasten frame members together, using a centralized rotary motion and torque lever to apply clamping force, eliminating the need for manual adjustments and providing a stable, flat workspace for frames of various sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional corner-by-corner clamping methods are used, then small to medium frames can be assembled, but large frames over 3 feet cannot be properly supported to maintain flatness and squareness
Solution Approach 1:
The clamping system is divided into multiple independent clamps positioned at different locations along the frame members. Each clamp can independently apply clamping force to different sections of the frame, allowing the system to handle frames of various sizes while maintaining precision through distributed support points rather than relying on a single clamping mechanism
Solution Approach 2:
The parallel rails act as intermediary elements that connect and coordinate the movement of multiple clamps. The rails ensure that all clamps move synchronously and maintain proper alignment, providing the necessary support structure to maintain flatness and squareness across large frame assemblies while enabling adaptability to different frame sizes
2Manufacturing precision
If multiple independent screw clamps are used at each corner, then frame members can be adjusted to achieve right angles, but manual intervention and adjustment time increase significantly
Solution Approach 1:
Multiple clamps are merged into a synchronized system where a single operator action moves all clamps simultaneously along the parallel rails. This combines the functions of multiple independent clamps into one coordinated mechanism, maintaining right angle accuracy through synchronized movement while dramatically reducing the time and manual intervention required compared to adjusting each clamp independently
Solution Approach 2:
The parallel rail system provides self-alignment and self-positioning features that guide the clamps into proper positions without requiring manual measurement or adjustment. The rails inherently maintain the geometric relationships needed for right angles, allowing the system to self-correct and self-position while minimizing operator intervention to simple activation rather than continuous adjustment
3Manufacturing precision
If extension wings with sliding rails are added to provide large flat workspace, then large frames can be assembled with proper support, but device complexity and space requirements increase
Solution Approach 1:
The extension wings with sliding rails serve multiple functions: they provide the large flat workspace needed for large frame assembly, guide and synchronize clamp movement, provide structural support for maintaining flatness, and enable adaptability to different frame sizes. By consolidating these multiple functions into a single integrated structure, the system achieves high precision without proportionally increasing complexity
Solution Approach 2:
The sliding rails transform the static extension wing structure into a dynamic system where clamps can move along predetermined paths. This dynamic capability allows the same structure to accommodate frames of various sizes while maintaining proper support and alignment, achieving versatility and precision without requiring multiple separate complex structures for different frame sizes
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 precise and efficient assembly of large frames by synchronously positioning clamps to form right angles, reducing manual effort and space requirements, while ensuring all frame members remain in a flat plane, and allowing for easy storage and versatile use of the machine.
Implementation Method 1
parallel rails that guide the miter clamps to move synchronously
Implementation Method 2
centralized rotary motion and torque lever to apply clamping force
Data Source
AI summary
A Synchronous Positioning Frame Assembly Machine having a plurality of extension wings (48) arranged to precisely locate miter clamps (40) containing captive sliding rails (46) that create a secondary motion to connect small and large frame members. Artist canvas frames, picture frames and other rectangular or square frames such as mirror frames made from mitered members being joined with glue or other mechanical means are precisely brought together at right angles and in a flat plane. Rotary motion of a central rotating shaft (54) linked (50) to the sliding rails (46) positions the clamps (40). A mechanically or manually operated torque lever (56) with knob (58) provides the prime mover force that moves the clamps in a synchronized manner while applying a clamping force to hold the frame members A, B, C, D together with a ratchet (68) and pawl (88) stop for the required assembly time of glue cycle, manual or mechanical fasteners.