Zero-Point Clamping System for Rapid Workpiece Positioning
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Solution Overview
Problem
The existing positioning and clamping systems for processing machines are tedious and time-consuming, often requiring extensive alignment and setup procedures, which can exceed the actual machining time.
Innovation Solution
A zero-point positioning and clamping system featuring a positioning bolt and pocket interaction, combined with a clamping and releasing tool using an eccentric bolt, lever, and pull-out pawl, allows for precise and rapid alignment and clamping of workpieces, ensuring stable contact and easy insertion and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional positioning and clamping systems are used, then workpieces can be secured for machining, but the alignment and setup procedures are tedious and time-consuming
Solution Approach 1:
The system employs pre-positioned positioning pockets and positioning bolts that are prepared in advance on the workpiece and holding device. The positioning bolts are pre-installed on the workpiece at specific locations, and the holding device has corresponding positioning pockets ready to receive them. This preliminary preparation eliminates the need for time-consuming alignment procedures during actual setup, as the components are designed to mate directly without adjustment.
Solution Approach 2:
The positioning bolt serves as an intermediary element between the workpiece and the holding device. It transfers the positioning function from complex alignment procedures to a simple insertion operation. The positioning bolt with its specific geometry (including the engagement section and circular groove section) acts as a mediator that enables precise positioning through a straightforward mechanical interface, eliminating the need for tedious alignment.
2Manufacturing precision
If complex alignment procedures are used to ensure positioning accuracy, then machining precision can be guaranteed, but the setup time exceeds the actual machining time
Solution Approach 1:
The positioning features (pockets and bolts) are designed and prepared in advance during workpiece manufacturing and holding device setup. This preliminary action ensures that when the workpiece needs to be machined, the positioning infrastructure is already in place, eliminating the need for time-consuming alignment procedures and significantly improving overall productivity.
Solution Approach 2:
The positioning system is designed to be self-aligning through the geometric relationship between the positioning bolt and positioning pocket. The workpiece automatically positions itself relative to the holding device through this self-service mechanism, without requiring external alignment tools or procedures, thus maintaining high machining precision while dramatically reducing setup time.
3Reliability
If conventional clamping tools are used, then workpieces can be secured, but the clamping and release operations are time-consuming
Solution Approach 1:
The clamping function is segmented into distinct operational phases: positioning (insertion of positioning bolt), clamping (engagement of clamping device), and release (removal of clamping device). This segmentation allows each function to be performed independently and efficiently. The positioning and clamping operations are separated, with positioning occurring first through the positioning bolt, followed by rapid clamping, enabling quick setup and release cycles while maintaining reliable clamping stability.
4Measurement precision
If precise positioning is achieved through multiple adjustment steps, then alignment accuracy is improved, but the number of operation steps increases
Solution Approach 1:
The positioning bolt acts as an intermediary that consolidates multiple alignment operations into a single insertion step. Its specific geometry (with engagement section and circular groove section) enables it to simultaneously establish positional relationships in multiple directions, eliminating the need for multiple adjustment steps while maintaining high alignment accuracy.
Solution Approach 2:
The complex alignment procedure is extracted and replaced by the standardized positioning bolt interface. Instead of performing multiple adjustment operations, the system extracts the positioning function into a dedicated component (the positioning bolt) that achieves accurate alignment through its design alone, significantly reducing the number of operation steps required.
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
This system enables efficient and precise positioning of workpieces, reducing setup time and ensuring accurate machining within permissible tolerances, while allowing for easy clamping and release without disturbing the workpiece during processing.
Implementation Method 1
The positioning of the cylindrical clamping section and the lever connected to it eccentrically to the bearing section makes it possible to apply a force to the lever of the clamping and release tool in such a way that it can act more strongly on the eccentric bolt and further on a workpiece to be clamped via a lever effect.
Data Source
Figure 1a~1d
Figure 2a~2b
Figure 3a~3d
AI summary
Positioning and clamping system for positioning and clamping at least one workpiece (7) on at least one machine tool, wherein at least one positioning bolt (4) is connected to the workpiece (7), wherein at least one positioning pocket (2) is connected to at least one holding device (6), wherein the workpiece (7) is positioned in the positioning pocket (2) with the positioning bolt (4) and is releasably clamped to the positioning pocket (2) by means of a clamping and releasing tool (1).