Tube Locator Plate for Precise Weld Alignment Without Fixtures
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Solution Overview
Problem
In metal fabrication, structural tube members require precise positioning and temporary support for welding, which is challenging due to the need for tight tolerances and complex geometries, often compromising structural integrity and requiring skilled labor, especially in DIY and remote assembly scenarios.
Innovation Solution
A non-structural locator device, such as a plate with fasteners and interferences, is used to precisely position and temporarily hold structural tube members in place for welding, allowing for precise alignment and concealment within the assembly, eliminating the need for additional weld fixtures and enabling novice fabricators to achieve professional-quality results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tab and slot connections are used to position tube members, then positioning precision is improved, but structural integrity is compromised due to material removal and sharp corners
Solution Approach 1:
The patent introduces a locator device as an intermediary component that positions tube members without requiring modifications to them. The locator device includes a positioning element that engages with the tube member's outer perimeter and a support element that contacts the tube member's inner sidewall, enabling precise positioning while preserving the tube member's structural integrity by avoiding material removal or sharp corners
Solution Approach 2:
The locator device is divided into separate functional elements: a positioning element for external engagement and a support element for internal support. This segmentation allows each element to perform its specific function independently, with the positioning element providing location accuracy and the support element maintaining structural integrity without requiring modifications to the tube members
2Stability of the object's composition
If clamps are used to hold tube members in position, then positioning stability is improved, but accessibility for welding is reduced
Solution Approach 1:
The patent removes the clamping function from the positioning system entirely. Instead of using clamps that physically constrain the tube members, the locator device uses a positioning element and support element that guide and stabilize the tube members through geometric engagement, eliminating the need for clamps and thereby improving welding accessibility
3Adaptability or versatility
If tube members are physically held by operators, then assembly flexibility is improved, but positioning precision deteriorates
Solution Approach 1:
The locator device enables the tube members to self-position through geometric engagement. The positioning element engages with the outer perimeter and the support element contacts the inner sidewall, creating a self-aligning system that achieves precise positioning without requiring operator skill or manual adjustment, while still allowing assembly flexibility
4Manufacturing precision
If locator devices are fastened to tube members, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent combines the positioning and support functions into a single integrated locator device. The positioning element and support element work together as one unit, eliminating the need for separate positioning fixtures and support structures, thereby reducing overall device complexity while maintaining high positioning accuracy
Data Source
AI summary
The present disclosure is for a metal fabrication locator device that is a plate, or other object as described herein, that is fastened to the tangent face of a receiving tube. A mating tube may then slide over the metal fabrication locator device such that the perimeter of the metal fabricator locator device biases the inside sidewall of the mating tube to precisely align it on the receiving tube. This eliminates the use of additional weld fixtures for positioning of tube members in a metal fabrication assembly. This also allows an end user to construct and weld a product together on their own with precise assembly. Also disclosed herein are methods of manufacture and assembly of a metal fabrication assembly using a metal fabrication locator device.