Toolless Sensor Mounting with Lever-Operated Clamp Tightener
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Solution Overview
Problem
In industrial environments, accessory devices like cameras and sensors require frequent positional adjustments due to changes in production runs or equipment configurations, often necessitating tool retrieval for alignment, which can be inconvenient and inefficient, especially when adjustments are needed outside of regular assembly tasks.
Innovation Solution
A mounting apparatus with a device-receiving mount allowing adjustment in at least one degree of freedom, utilizing a clamp ring and lever-operated clamp tightener for secure clamping, enabling tool-free or minimal-tool adjustments and easy removal/replacement of accessory devices without affecting their alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mounting methods are used, then secure positioning is achieved, but tool retrieval is required for adjustments causing downtime
Solution Approach 1:
The mounting apparatus enables the accessory device to be adjusted and secured without external tools. The manually threaded fastener allows technicians to perform adjustments using only hand power, eliminating the need to retrieve tools from toolboxes or waiting for tool availability, thus making the system self-sufficient for adjustment operations
Solution Approach 2:
The mounting apparatus separates the adjustment function from the securing function. The manually threaded fastener handles initial positioning and alignment adjustments, while the lever-operated clamp tightener provides final secure locking. This segmentation allows each function to be optimized independently and performed with appropriate manual operation
2Adaptability or versatility
If frequent adjustments are made, then alignment with conveyer changes is achieved, but alignment consistency may be compromised
Solution Approach 1:
The device-receiving mount incorporates pre-configured adjustment mechanisms with cross-section surfaces designed for precise positioning. The mounting apparatus allows technicians to make preliminary alignment adjustments using the manually threaded fastener, establishing a stable baseline position before final securing, thereby maintaining alignment consistency across frequent adjustments
Solution Approach 2:
The mounting apparatus transitions from a static fixed position to a dynamic adjustable position. The lever-operated clamp tightener provides a mechanical advantage system that allows the accessory device to be securely locked at any adjusted position, maintaining precision while accommodating frequent alignment changes due to conveyer reconfigurations
3Ease of operation
If manual threading is used, then ease of adjustment is improved, but clamping tension is insufficient compared to full tension
Solution Approach 1:
The clamping process occurs in two distinct periodic stages: first, the manually threaded fastener is used to establish initial positioning and achieve sufficient clamping tension for alignment work; second, the lever-operated clamp tightener is engaged to apply full clamping tension for final secure locking. This periodic application of different tension levels optimizes both ease of operation and clamping force
Solution Approach 2:
The lever-operated clamp tightener acts as an intermediary mechanical advantage device between the manually threaded fastener and the final clamping action. It takes the partially tightened fastener and amplifies the applied force through lever mechanics to achieve full clamping tension, bridging the gap between manual adjustment capability and required secure locking force
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
Facilitates stable and efficient positioning of accessory devices with minimal tool requirements, allowing for adjustments in various degrees of freedom and maintaining alignment consistency during device changes, thus enhancing operational flexibility and reducing downtime in industrial settings.
Implementation Method 1
The lever-operated clamp tightener acts on the manually threaded fastener to releasably tighten the clamping mechanism beyond that achieved by manually threading the manually threaded fastener
Data Source
AI summary
Mounting apparatus is used for supporting an accessory device, e.g., a sensor, in a manner permitting adjustment. An accessory device-receiving mount is fixable to the accessory device and has at least one surface forming a cross-section permitting adjustment in at least one degree of freedom. A clamp ring engages the device-receiving mount at the surface, so that the cross-section permitting adjustment. A clamping mechanism selectively clamps the clamp ring and includes a manually threaded fastener and a lever-operated clamp tightener. The lever-operated clamp tightener acts on the manually threaded fastener to releasably tighten the clamping mechanism beyond that achieved by manually threading the manually threaded fastener, permitting manually threading the clamping arrangement at a maximum tension less than a full tension applied by the lever-operated clamp tightener.