Adjustable Welding Jig for Single-Person Pipe Rail Alignment
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Solution Overview
Problem
In remote rural areas, such as outback Australia, welding horizontal members to vertical structures is challenging due to the lack of additional personnel to hold the members in place during the welding process, and existing clamping systems are inadequate for single-person operation.
Innovation Solution
A welding jig comprising a base with a clamp, a frame connected by a threaded member, sliding supports, and vise parts that allow for adjustable clamping and positioning of horizontal members relative to vertical members, enabling single-person operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bracket is fixed to a vertical member using a pipe chain or strap clamp, then the vertical member can be secured, but the ability to hold a bracket and simultaneously manipulate a chain clamp assembly while maintaining accurate adjustment capability is beyond the ability of a single person
Solution Approach 1:
The welding jig is designed to be self-adjusting and self-positioning, with features such as the self-centering horizontal member positioning mechanism and the automatic locking of adjustment mechanisms, eliminating the need for a second person to hold components while adjustments are made
Solution Approach 2:
The positioning system is divided into separate coarse and fine adjustment mechanisms that operate independently, allowing each to be adjusted separately and then locked in place, simplifying the overall adjustment process for a single operator
2Manufacturing precision
If multiple adjustment mechanisms are provided for precise positioning, then positioning accuracy is improved, but the device complexity increases
Solution Approach 1:
The positioning system is segmented into coarse adjustment mechanisms (first supports with predetermined positions) and fine adjustment mechanisms (vise parts with threaded engagement), where each segment performs a specific function and can be independently adjusted and locked
Solution Approach 2:
The adjustment mechanisms are designed to be dynamically adjustable during operation, with the capacity to transition between coarse positioning and fine tuning, and then lock into place to maintain precision without requiring continuous active adjustment
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 jig enables secure and precise holding of horizontal members in place, allowing a single operator to weld without assistance, through coarse and fine adjustments for vertical and horizontal positioning.
Implementation Method 1
a frame interconnected to said base by a first threaded member constituting a second, fine, vertical adjustment mechanism
Implementation Method 2
first and second vise parts each threadably mounted on a corresponding one of said supports and movable towards and away from each other to constitute a vise mechanism
Implementation Method 3
a base having a clamp able to clamp the base to the vertical member
Implementation Method 4
the base clamp comprises a first chain able to be tightened about the vertical member
Data Source
AI summary
A welding jig (3, 103, 203) for holding a horizontal member relative to a vertical member is disclosed. The jig has a base (5, 105, 205) having a clamp (8, 108, 208) able to clamp the base to the vertical member and constituting a first, coarse, vertical adjustment mechanism. A frame (11, 111, 211) is interconnected to the base by a first threaded member (12, 112, 212) constituting a second, fine, vertical adjustment mechanism. A pair of supports (21, 121, 221) is slidingly mounted on the frame and movable between predetermined positions to constitute a first, coarse, horizontal adjustment mechanism. First and second vise parts (43, 44, 143, 144, 271, 272) each threadably mounted on a corresponding one of the supports and movable towards and away from each other constitute a vise mechanism for clamping the horizontal member.