Transducer-Actuator System for Automatic Part Alignment
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Solution Overview
Problem
Current methods for aligning parts on machine tools, especially in constrained environments like gloveboxes, are time-consuming and prone to human error due to limited visibility and access, requiring manual adjustments and precise positioning with tools like position transducers and hammers, which are inefficient and inaccurate.
Innovation Solution
A transducer-actuator system that combines a machine-mounted probe for position measurement with a linear actuator to automatically align parts by determining misalignment and executing controlled taps to correct positioning, using a computer-based interface and spindle encoder for precise alignment without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment operations are performed in a glovebox or constrained environment, then human operators can perform alignment tasks, but the operation time increases significantly and accuracy decreases due to limited visibility and access
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated system consisting of a position transducer for measurement and a linear actuator for correction. The transducer measures part runout automatically, and the actuator applies precise mechanical taps to correct misalignment, eliminating the need for manual operations in constrained environments like gloveboxes.
Solution Approach 2:
The alignment system performs self-service by automatically measuring part position with the transducer, calculating required corrections, and executing alignment taps through the linear actuator without human intervention. The system autonomously completes the entire alignment process, including measurement, calculation, and correction execution.
2Measurement precision
If multiple adjustments and rechecks are made to obtain desired alignment, then measurement precision improves, but the number of operations increases and total time increases
Solution Approach 1:
The system implements feedback by continuously measuring part runout with the position transducer after each actuator tap, comparing the measurement against target alignment specifications, and automatically adjusting subsequent tap positions and forces. This closed-loop feedback enables high precision alignment in fewer operations compared to manual methods.
Solution Approach 2:
The system performs preliminary measurement and calculation of the exact correction needed before executing alignment taps. The transducer measures runout, the control system calculates optimal tap parameters, and then the actuator executes the predetermined correction sequence, minimizing iterative adjustments.
3Extent of automation
If automated part centering is implemented, then human effort and operation time are reduced, but system complexity increases due to integration of transducer and actuator components
Solution Approach 1:
The patent merges the measurement function (position transducer) and correction function (linear actuator) into a single integrated alignment system. The transducer and actuator are coordinated through a control system that combines measurement data, calculates corrections, and executes alignment, creating a unified automated solution despite the added complexity.
4Measurement precision
If position transducer is used to sweep surface and establish relationship to machine datum, then measurement accuracy is achieved, but the operation requires manual intervention and multiple adjustments
Solution Approach 1:
The patent replaces manual operation of the position transducer with automated control. The transducer remains the measurement sensor, but its movement, data collection, and interpretation are fully automated through the control system, which processes transducer signals and coordinates actuator responses without manual intervention.
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
This system enables faster, more accurate, and repeatable part alignment, reducing human effort and improving precision, even in limited access situations, by using a self-contained transducer-actuator assembly that can be mounted on machine tools, effectively addressing the inefficiencies of manual alignment methods.
Implementation Method 1
The part is tapped into place with a linear actuator driven by a voice coil motor
Implementation Method 2
a position transducer mounted to a machine axis or an electronic gauge for example
Implementation Method 3
The part is tapped into place with a linear actuator
Data Source
AI summary
Systems and methods for performing on-machine measurements and automatic part alignment, including: a measurement component operable for determining the position of a part on a machine; and an actuation component operable for adjusting the position of the part by contacting the part with a predetermined force responsive to the determined position of the part. The measurement component consists of a transducer. The actuation component consists of a linear actuator. Optionally, the measurement component and the actuation component consist of a single linear actuator operable for contacting the part with a first lighter force for determining the position of the part and with a second harder force for adjusting the position of the part. The actuation component is utilized in a substantially horizontal configuration and the effects of gravitational drop of the part are accounted for in the force applied and the timing of the contact.