Truss Assembly Table Jigging with Rod Sag Prevention
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Solution Overview
Problem
Existing automatic jig systems for truss assembly tables face issues with debris accumulation, rod sagging, and maintenance due to the use of screw-threaded rods, leading to inefficiencies and potential system failures, especially in environments with dust and debris.
Innovation Solution
A system utilizing a motor-controlled threaded rod with a Nylatron insert and steel tubular support member, along with self-lubricating glide pads and support blocks, to maintain smooth operation, prevent debris accumulation, and withstand abuse, while eliminating the need for lubricants and reducing wear and tear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If screw-threaded rods are used to move jig pucks along slots, then automatic positioning is achieved, but debris accumulation on the rods causes friction and system failure
Solution Approach 1:
The patent extracts the harmful function of the threaded rod surface by introducing a separate lubrication system that applies lubricant only where needed at the interface between the rod and puck, rather than coating the entire rod surface. This prevents debris accumulation while maintaining the automatic positioning function.
Solution Approach 2:
The patent introduces lubricant as an intermediary substance between the threaded rod and jig puck to reduce friction and prevent debris adhesion. The lubrication system acts as a mediator that enables reliable automatic positioning by eliminating the harmful interaction between debris and the rod-puck interface.
2Ease of operation
If lubricant is applied to threaded rods to facilitate puck movement, then movement is smoothed, but debris is trapped and held on the rod surface
Solution Approach 1:
The patent extracts the harmful effect of excessive lubricant by providing lubrication only at the specific interface where the puck contacts the rod, rather than coating the entire rod surface. This is achieved through a lubrication system that delivers lubricant locally to the contact point, maintaining smooth movement while preventing debris trapping.
Solution Approach 2:
The patent applies lubricant locally only at the interface between the threaded rod and jig puck, rather than uniformly across the entire rod surface. This localized lubrication provides the necessary smoothness for puck movement while minimizing the surface area where debris can accumulate, thereby resolving the contradiction between ease of operation and harmful factors.
3Strength
If threaded rods are positioned below slots in a closed channel, then structural support is provided, but debris is held in close proximity to the rods from bottom and top
Solution Approach 1:
The patent extracts the harmful accumulation of debris in closed channels by transitioning to an open-channel design where debris can fall through to the floor. The threaded rods are repositioned and supported in a manner that maintains structural strength while eliminating the enclosed space where debris would accumulate and contact the rods.
Solution Approach 2:
Instead of enclosing the threaded rods in closed channels that trap debris, the patent inverts the approach by using open channels that allow debris to fall away from the rods. This reversal of the channel design eliminates the harmful proximity of debris to the rods while maintaining the necessary structural support.
4Length of moving object
If long threaded rods (12-14 feet) are used for truss jigging, then full slot coverage is achieved, but the rods sag under their own weight and whip when rotated
Solution Approach 1:
The patent segments the long threaded rod into multiple sections by introducing intermediate support blocks that divide the rod's span into shorter effective lengths. These support blocks are positioned along the rod's length to provide localized support, preventing sagging and reducing whip during rotation while maintaining the overall 12-14 foot length needed for full slot coverage.
Solution Approach 2:
The patent addresses the stability issue by adding support blocks that extend in a different dimension (vertically below the slot) to provide intermediate support points along the rod's length. This dimensional addition creates multiple support planes that prevent the rod from sagging and reduce whip during high-speed rotation.
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
The system enables quick setup, reduces wear on components, prevents debris accumulation, and withstands extreme abuse, ensuring smooth operation and extended service life without the need for frequent maintenance.
Implementation Method 1
self-lubricating Nylatron inserts
Implementation Method 2
glide pads
Data Source
AI summary
A jig positioning system for use on a truss assembly table. The puck assembly 108 has a puck 109 positioned at least partially above the table top 105 with the puck 109 connected to a carriage 110 positioned at least partially below the table top. The puck assembly 108 moves along slots 118 in the table top 105. A threaded rod 102 extends through a threaded passageway 103 in the carriage 110, so, when the threaded rod rotates, the puck assembly moves along a corresponding slot in the table. A rod support member 116 extends along the length of the threaded rod 102 and is positioned below the threaded rod 102, the support member 116 contacting the carriage and, thereby, preventing the threaded rod from excessive sagging. A debris path is provided along both sides of the support member 116.