Open Triangular Brace for Three-Axis Welding Alignment
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Solution Overview
Problem
Existing three-axis welding vises are complex, expensive, and cumbersome due to built-in clamps and bench-mounting requirements, making them impractical for positioning multiple units to hold structures together for welding, and magnetic two-axis angles are limited in functionality and prone to dislodging when used for multi-joint frames.
Innovation Solution
A simple, open triangular brace made of rigid material with removable and rotatable planes, allowing for alignment and clamping of workpieces, which can be used in multiple locations and is affordable, lightweight, and stackable, using clamps or magnets for securing, and can be adapted for high-heat welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional three-axis welding vises are used, then clamping and alignment function is provided, but device complexity and cost increase due to built-in clamps and bench-mounting requirements
Solution Approach 1:
The invention extracts the clamping function from the brace itself and assigns it to separate, removable clamps. The brace is designed as a simple triangular structure without integrated clamps or mounting holes, allowing it to be used with various clamping methods (C-clamps, magnets, etc.) depending on the workpiece and application.
Solution Approach 2:
The triangular brace design is universal and can be used in multiple configurations and applications. It can be employed with different clamping methods (mechanical clamps, magnetic attachment), on different workpiece materials, and in various positions, making it adaptable to diverse welding scenarios without requiring specialized features.
2Manufacturing precision
If multiple traditional three-axis welding vises are positioned to hold structures together, then alignment is achieved, but portability and ease of positioning decrease due to weight and complexity
Solution Approach 1:
The invention divides the clamping system into separate functional components: the triangular brace provides alignment and structural support, while separate clamps provide the clamping force. This segmentation allows each component to be optimized independently and makes the system more portable and easier to position.
Solution Approach 2:
The design favors simple, lightweight braces that can be easily replaced or repositioned over expensive, heavy traditional vises. The braces are designed to be affordable and portable, suitable for temporary welding fixtures rather than permanent bench-mounted equipment.
3Ease of manufacture
If magnetic two-axis angles are used for multi-joint frames, then magnetic attachment is provided, but reliability decreases due to risk of dislodging under high-heat welding conditions
Solution Approach 1:
The invention allows for localized heat management by designing the triangular brace with specific geometric features and material considerations. The triangular geometry and potential for insulation or heat-sinking features address thermal issues at critical locations without requiring the entire system to be heat-resistant, maintaining reliability under welding conditions.
4Force
If traditional three-axis welding vises are designed with built-in clamps, then clamping force is provided, but adaptability decreases for different workpiece configurations
Solution Approach 1:
The clamping function is extracted from the brace and implemented through separate, removable clamps. This allows the user to select different clamping methods (C-clamps, magnets, vise-grips) based on the specific workpiece configuration, material type, and welding requirements, significantly increasing adaptability.
Solution Approach 2:
The triangular brace serves as a universal alignment and support structure that can be combined with various clamping methods. The design accommodates different workpiece shapes, sizes, and materials by allowing flexible clamping approaches rather than requiring integrated, fixed clamping mechanisms.
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 efficient, cost-effective, and portable alignment and clamping of multiple workpieces for welding, reducing the complexity and cost associated with traditional three-axis welding vises and overcoming the limitations of magnetic two-axis angles.
Implementation Method 1
For magnetic steel workpieces, an alternative to clamping the triangular brace to the workpieces will be to fix magnets into the triangular brace
Data Source
AI summary
An open triangle made of rigid material planes each joined ninety degrees to one another and of sufficient thickness, rigidity, precision and construction for the triangle as a whole to serve as a brace for clamping, aligning, and joining workpieces, especially three workpieces at ninety degrees to one another; the opening of the triangular brace serving as a space for the operation of joining the workpieces, especially joining by means of high-heat welding but also by other means of joining, like drilling and fastening with bolts; the triangular brace being constructed of one piece, or a plurality of pieces in which one plane or all planes of the brace are removable and re-attachable, or rotatable in and out of position, by means of screws, bolts, pins, interlocking tongue-and-groove, magnets, axle for rotation, or other secure means.