Truss Assembly Table Puck Assembly With Tight-Tolerance Bronze Insert
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Solution Overview
Problem
Existing truss assembly tables suffer from dust and debris accumulation between the drive rod and mounting block, which inhibits the smooth operation of the puck assembly.
Innovation Solution
The introduction of a bronze block insert with tight tolerances between the outer threads of the drive rod and inner threads of the block insert to limit dust and debris, combined with a mounting block made of nylon plastic filled with molybdenum disulfide lubricant powder, ensures smooth operation of the puck assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional puck assemblies are used with spaces between the drive rod and mounting block, then the structure is simpler and easier to manufacture, but dust and debris accumulate in the spaces causing operational inhibition
Solution Approach 1:
A block insert is introduced as an intermediary component between the drive rod and mounting block. This insert fills the gap space, preventing dust and debris accumulation while maintaining the mechanical connection. The block insert acts as a mediator that eliminates the harmful empty space without requiring a complete redesign of the entire puck assembly structure.
Solution Approach 2:
The tolerances between the outer threads of the drive rod and the inner threads of the block insert are set to tight specifications. This parameter change reduces the gap size to a level that prevents debris accumulation while still allowing for smooth operation and assembly. The tight tolerance parameter transforms the problematic large gap into a functional minimal clearance.
2Object-affected harmful factors
If tight tolerances are used between the drive rod and block insert, then debris accumulation is limited, but manufacturing precision requirements increase
Solution Approach 1:
The block insert serves as a mediator that can be manufactured with standard tolerances and then assembled to achieve the tight overall fit. By introducing this intermediate component, the system achieves tight effective tolerances without requiring the drive rod and mounting block themselves to be manufactured with extremely tight tolerances, thus reducing the overall manufacturing precision burden.
Solution Approach 2:
The connection system is segmented into multiple components (drive rod, block insert, mounting block) rather than being a single integrated part. This segmentation allows each component to be manufactured with more relaxed tolerances individually, while the cumulative effect of the assembled components achieves the desired tight overall tolerance to prevent debris accumulation.
3Productivity
If the puck assembly operates smoothly without debris, then the motor operates more effectively, but the device requires more complex material selection and configuration
Solution Approach 1:
The block insert is specified to be made of bronze, which is a composite material combining copper and tin. This composite material provides both wear resistance for smooth operation and self-lubricating properties that prevent debris generation. The use of this specific composite material enhances productivity while the design keeps the overall structural complexity manageable.
Solution Approach 2:
The material properties are changed by selecting bronze for the block insert, which has specific friction and wear characteristics that promote smooth operation. This parameter change in material selection directly improves the operational effectiveness and productivity of the truss assembly table by reducing friction and preventing debris accumulation in the threaded connection.
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
Prevents debris build-up, allowing the motor to operate more smoothly and effectively, enhancing the functionality of the truss assembly table.
Implementation Method 1
a mounting block made of nylon plastic filled with molybdenum disulfide lubricant powder
Data Source
AI summary
A truss assembly table having a plurality of puck assemblies each including a drive rod having outer threads, a mounting block, a block insert positioned in the mounting block, the block defining an inner first channel extending through the block insert from a first end surface to a second end surface, the inner first channel configured to receive the threaded drive rod such that the block insert is journaled about the drive rod, the block insert including inner threads mated with the outer threads of the drive rod, a puck, and a fastener assembly connecting the puck, the mounting block, and the block insert.