Toolless Ball-Lock Clamp With Torque Limiting for Precise Fixturing
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Solution Overview
Problem
Existing machine tooling clamps require tools for operation, which are cumbersome, difficult to use in tight spaces, and prone to damage, leading to reduced precision and increased maintenance costs.
Innovation Solution
A toolless machine tooling clamp featuring a hand-operable torque-limited rotation system coupled with a ball-lock pin assembly, utilizing a D-shaped shank and bushing configuration to provide secure clamping without the need for tools, incorporating a clutch plunger and spring mechanism to limit torque and prevent overtightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a tool-operated clamp mechanism is used, then sufficient clamping force can be achieved, but the operation becomes cumbersome and difficult in tight spaces
Solution Approach 1:
The clamp mechanism is designed to be self-operating through a spring-loaded trigger system. When the trigger is actuated, it releases the locking balls, allowing the spring to automatically advance the clamp into the locked position against the workpiece. This eliminates the need for external tools while maintaining sufficient clamping force through the spring mechanism.
Solution Approach 2:
The clamp incorporates spherical locking balls that engage with corresponding recesses in the clamp mechanism. These balls provide smooth rotational movement and reliable locking engagement, enabling easy one-handed operation while generating adequate clamping force through the mechanical advantage of the spherical geometry.
2Productivity
If manual torque is applied without limitation, then clamping speed may increase, but overtightening and damage risk increase
Solution Approach 1:
The clamp mechanism incorporates a spring-loaded trigger system that provides inherent torque feedback. As the clamp approaches full engagement, the spring force naturally decreases, providing tactile feedback to the operator that the clamping action is complete. This prevents overtightening without requiring external torque limiting devices, maintaining both speed and safety.
Solution Approach 2:
The spring mechanism is pre-loaded to provide a cushioning effect that automatically limits the maximum clamping force. The spring absorbs excess energy and prevents the trigger mechanism from applying damaging torque to the workpiece, ensuring safe operation from the outset without requiring operator judgment or additional protective devices.
3Reliability
If traditional ball-lock elements are used, then secure locking can be achieved, but tool dependency and maintenance requirements increase
Solution Approach 1:
The clamp mechanism merges the ball-lock element, spring-loaded trigger, and torque-limiting features into a single integrated assembly. The locking balls are spring-loaded and automatically engage with the clamp body when the trigger is actuated, eliminating the need for separate tool-operated locking mechanisms. This integration maintains reliable locking while simplifying the overall device structure and reducing maintenance requirements.
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 secure clamping of workpieces without tools, reducing the risk of damage and maintenance, while improving precision and ease of use by limiting torque and preventing overtightening, thus enhancing machining accuracy and efficiency.
Implementation Method 1
incorporating a clutch plunger and spring mechanism to limit torque and prevent overtightening
Implementation Method 2
utilizing a D-shaped shank and bushing configuration to provide secure clamping
Data Source
AI summary
A toolless clamp, toolless clamping system, and methods of use comprising a torque-limited rotation system operatively coupled to a ball-lock pin. The rotational system may be manually tightened without use of a tool to advance a spring-actuated spindle of the ball-lock system to engage lock balls. The clamp shank has a D-shaped cross-section corresponding to a D-shaped bushing in the fixture to inhibit rotational movement of the clamp during tightening. The clamp and D-shaped bushing may be used with a receiver bushing in the subplate to receive and retain the lock balls when deployed from the ball-lock pin.