MACHINING FIXTURE ASSEMLY AND METHOD INCLUDING AN ADAPTOR
Technical Field
The present invention relates generally to machining operations. More particularly, the invention relates to a machining fixture assembly including an adaptor and a method of interchanging workpiece retaining members.
Background Art
Systems for the manufacture of machined parts have historically been developed as a function of the volume of the parts to be produced. Where a large quantity of parts are to be manufactured in a continuous or near continuous manner, as occurs in the automotive industry, specialized machinery is developed for the machining and shaping of a particular part.
In general, the development and capital equipment costs for such specialized machining centers, which may vary by brand or type, is very high, although the initial costs may be overcome by the large volume of parts produced resulting in lower overall piece-part costs when compared to other types of machining systems. While systems of this type are well suited for large volume runs, their specialized design is such that they have a low adaptability for the manufacture of parts outside of their design specifications. Where machined parts are required in low to moderate volumes, in contrast to high volumes, the design costs associated with dedicated or specially designed machine systems may be prohibitive.
Various types of machining systems have been developed to meet the requirements fcrthe low to moderate volume manufacture of machined parts. Machining fixture assemblies may include a fixture block, known as a "tombstone", to hold work pieces in place during machining. The fixture block is specifically adapted to hold workpiece(s) to be machined on a particular brand or type of machining center. This specificity of design does not allow the fixture block to be used with other brands or types of machining centers. A fixture block is specifically configured to hold workpieces of a particular design, and the fixture block is often provided with hydraulically or pneumatically-actuated clamps for releasably securing the workpiece(s) to the fixture block.
The fixture block is supported on a gage pallet, also specifically adapted to the particular brand or type of machining center, wherein the fixture block and gage pallet are provided with means for attaching the two at their interface. The design of the fixture block-to-gage pallet interface is typically specific to the gage pallet and usually requires that fixture blocks be designed to fit on gage pallets of a design unique to one of several different brands or types of machining centers. The gage pallet and, thus, the gage pallet-to-fixture block interface can vary from manufacturer to manufacturer and further may be proprietary in nature. Therefore, fixture blocks are generally not interchangeable between different makes
of machining centers and gage pallets. Because different machining sources may use different brands or types of machining centers, part machining operations often cannot be readily accommodated at different machining sources. Further, the incompatibility of one brand of fixture blocks to another brand of gage pallets may limit the ability to fully realize the full potential capacity of a machining center to which the fixture block(s) for the machining of only one of a plurality of part fits. The incompatibility also contributes to the prohibitively high production cost of machined parts in low to moderate volumes.
Another shortcoming associated with many machining systems relates to the interchanging of fixture blocks on the machining center gage pallets, which can occur quite frequently for parts manufactured in low to moderate volumes. The interchange may require two or more skilled laborers to ensure accurate positioning and alignment of the oftentimes heavy fixture blocks on the gage pallet(s). A first operator may operate a lift assembly for raising and lowering the fixture block relative to the gage pallet. A second operator may align and attach the fixture block and the gage pallet. The fixture block interchange may require a substantial amount of time thereby reducing the productivity of the machining system and raising machining costs.
In view of the above, it would be desirable to provide a strategy for adaptably interfacing fixture blocks to different machining center brands or types, and thus to different gage pallet designs, thereby eliminating the need to match a specific fixture block design to a specific gage pallet design.
In addition, it would be desirable to provide a strategy for relatively rapid positioning of a fixture block and the accurate alignment and attachment of a fixture block to its gage pallet that overcomes the aforementioned and other disadvantages.
Brief Description of Drawings
FIG. 1 is a schematic view of a prior art machining assembly; FIG. 2 is a schematic view of a machining assembly in accordance with one embodiment of the present invention;
FIG. 3 A is a perspective view of a workpiece retaining member and an adaptor, in accordance with a first embodiment of the inventive machining fixture assembly, the interfacing surfaces of the separable workpiece retaining member and adaptor shown 90° out of their operational orientation;
FIG. 3B is another perspective view of the fixture assembly of FIG. 3 A, showing the interfacing surfaces of the separable workpiece retaining member and adaptor;
FIG. 3C is a perspective view of the fixture assembly of FIG. 3A, showing the adaptor's bottom surface, which interfaces with the gage pallet of a machining center;
FIG. 4 is an exploded perspective view of a second embodiment of a machining fixture assembly in accordance with the present invention, and the gage
pallet and rotary table of a machining center;
FIG. 5 is an assembled perspective view of the machining fixture assembly and machining center pallet and table of FIG. 4, with workpieces shown attached to the workpiece retaining member via hydraulic clamping mechanisms;
FIG. 6 is an assembled perspective view of the machining fixture assembly and machining center pallet and table of FIG. 4, with workpieces shown attached to the workpiece retaining member via pneumatic clamping mechanisms; and
FIGS. 7A, 7B, and 7C are schematic views illustrating a method of interchanging two different workpiece retaining members to a common adaptor in a machining fixture assembly in accordance with one embodiment of the present invention.
Modes for Carrying Out the Invention
Referring to the drawings, wherein like reference numerals refer to like elements and the figures are not necessarily drawn to scale, FIG. 1 is a schematic view of a prior art machining fixture assembly , shown generally by numeral 10. Machining fixture assembly 10 includes a fixture block or tombstone 12 to which one or more workpieces (not shown) to be machined on a machining center (not shown) are temporarily attached, such as by pneumatically-actuated clamps (not shown). Fixture block 12 interfaces with and is attached directly to a gage pallet 14 having a design specific to the particular brand or type of machining center. The interface between fixture block 12 and gage pallet 14, therefore, is specific to the particular brand or type of machining center thereby not allowing the fixture block to be utilized on any other brand or type of machining center.
One or more locking members 16 provide means for retaining the fixture block 12 to the gage pallet 14 once they are appropriately positioned one to another. Gage pallet 14 is positioned on and attached to a base 18, which may comprise a controllably rotatable table or other supporting member. The interface between the fixture block and gage pallet is specifically designed, thus fixture blocks for use with one brand or type of machining center are generally not interchangeable with those of a different brand or type, each brand or type of machining center usually having its own gage pallet and base configuration, which may be of a proprietary design. The incompatibility between various fixture blocks and machining centers limits the ability to realize the foil potential capacity of a machining center, or otherwise limits a facility's machining capabilities or machining sourcing flexibility.
FIG.2 is a schematic view of a machining fixture assembly 20 in accordance with a first embodiment of the present invention. Assembly 20 comprises a workpiece retaining member 22 for retaining at least one workpiece (not shown). Workpiece retaining member 22 comprises at least one workpiece retaining member surface 24 and a workpiece retaining member interface surface 26. The design of workpiece retaining member surface 24 is specific to the particular workpiece(s) to be machined. However, the design of the workpiece retaining member interface surface 26 is standardized across a plurality of workpiece retaining members
22.
A gage pallet 40 supports the workpiece retaining member 22 through an adaptor 30 positioned substantially between the workpiece retaining member 22 and the gage pallet 40. Adaptor 30 is operably attached to the workpiece retaining member 22 at standardized interface 28 and the gage pallet 40 at customized interface 44. Adaptor 30 includes a first adaptor interface surface 32 and a second adaptor interface surface 34. First adaptor interface surface 32 cooperates with workpiece retaining member interface surface 26. Second adaptor interface surface 34 cooperates with gage pallet interface surface 42. Therefore, the design of adaptor 30 is specific to gage pallet 40, and thus typically specific to a particular brand or type of machining center.
Assembly 20 further includes one or more hydraulic members 36 and/or pneumatic members 38 for providing positioning, which includes lifting and lowering, of the workpiece retaining member 22 relative to the adaptor 30.
One or more locking members 48 provide means for retaining the workpiece retaining member 22 to the adaptor 30 once appropriately positioned and aligned one to another. Assembly 20 is positioned on a base 46, which may comprise a table or other supporting member. Those skilled in the art will recognize that the assembly 20 and its constituent components may vary without departing from the spirit and scope of the present invention.
FIGS. 3A and 3B are perspective views of a workpiece retaining member 50 and an adaptor 52, in accordance with a first embodiment of the machining fixture assembly, the interfacing surfaces of the separable workpiece retaining member and adaptor shown 90° out of their operational orientation. FIGS. 3A and 3B illustrate a first interface 75. First interface 75 is a standardized interface common to a plurality of specifically designed workpiece retaining members for machining various workpieces. Standardized interface 75 comprises a workpiece retaining member interface surface 54 and a first adaptor interface surface 56. Work piece retaining member interface surface 54 and first adaptor interface surface 56 include complementary components and connections. These complementary components and connections allow the interconnection of work piece retaining member 50 with features of the first adaptor interface surface 56. For example, pins 58 on the first adaptor interface surface 56 provide means for aligning the workpiece retaining member 50 relative to adaptor 52. Pins 58 correspond to pin apertures 60 formed within the workpiece retaining member interface surface 54.
In another example, one or more locking members 62 provide means for retaining the workpiece retaining member 50 to the adaptor 52 once they are appropriately positioned and aligned one to another.
Locking members 62 correspond to lock apertures 64 formed within the workpiece retaining member interface surface 54. In one embodiment, locking members 62 have a reduced diameter, substantially smaller than the size of the lock apertures 64, during positioning and alignment of me workpiece retaining member 50 to the adaptor 52. Once properly positioned, the locking members
62 may increase radially in size until obtaining a "tight fit" with the lock apertures
64 thereby providing a factional lock.
Adaptor 52 also includes one or more pneumatic members 70 and one or more hydraulic members 72 for providing clamping of workpieces to workpiece retaining member 50. One or more hydraulic couplings 74 provide means for operably attaching hydraulic lines to the hydraulic members 72 for supplying pressurized hydraulic fluid to the workpiece fixture clamps. One or more air couplings 76 may provide means for operably attaching air lines to the pneumatic members 70 for supplying pressurized air to pneumatically actuated workpiece fixture clamps. Those with skill in the art will recognize that the number and orientation of the above listed components may vary depending on the specific adaptor and work piece retaining member.
FIG. 3C is a perspective view of a second interface of the adaptor 52 shown in FIGS. 3A and 3B for operable attachment to a gage pallet. Second interface is a customized interface specific to a gage pallet of a single brand or type of machining center. Second interface comprises a second adaptor interface surface 80 of adaptor 52 that corresponds to a gage pallet interface surface of the gage pallet (not shown). For example, features of the second adaptor interface surface 80 include members that allow interconnection with features of the gage pallet interface surface. One or more apertures 82 may be formed within the adaptor 52 for receiving a like number of retaining members (e.g., bolts, clips, and the like) therein. Retaining members (not shown) may be received by a like number of apertures formed within the gage pallet for operably attaching the adaptor 52 to the gage pallet. In addition, the retaining members may include complementary part(s) appropriately positioned for providing fastening means, such as a complementary nut for a bolt retaining member.
In one embodiment, the adaptor 52 comprises a plate-like shape. In another embodiment the adaptor may comprise any number of geometric shapes for providing first and second adaptor interfaces between the workpiece retaining member and the gage pallet. Those skilled in the art will recognize that the aforementioned first and second adaptor interfaces may vary from the illustrated and described embodiment. Various changes and modifications may be made without departing from the spirit and scope of the present invention. For example, numerous strategies may be adapted for aligning, positioning, lifting, lowering, locking, retaining, and operably attaching a workpiece retaining member, an adaptor, and a gage pallet in accordance with the present invention.
FIG. 4 illustrates an exploded perspective view of a second embodiment of a machining fixture assembly 100 in accordance with the present invention, as well as the gage pallet and rotary table of the machining center. FIG. 5 illustrates an assembled perspective view of the machining fixture assembly 100, machining center pallet and table of FIG. 4. Machining fixture assembly 100 includes a workpiece retaining member 102 for retaining at least one workpiece 104. In FIG. 5, two workpieces 104 are shown. Workpiece retaining member 102 includes a
connector 106 positioned on a top surface 108. Connector 106 facilitates lifting, lowering, and positioning of the workpiece retaining member 102 by, for example, a lift assist member (not shown) positioned above the top surface 108.
In another or the same embodiment, one or more hydraulic members and pneumatic members may be positioned above and interface with the top surface 108 thereby facilitating the interchangeability of the workpiece retaining member 102. A lift frame may provide means for anchoring the aforementioned lift assist member as well as the hydraulic and pneumatic members positioned above the top surface 108. Lift frames are commonly used in operations for changing fixture blocks and thus are known to and may be implemented with the present invention by one skilled in the art.
Machining fixture assembly 100 includes a first interface 160 for connecting the workpiece retaining member 102 to adaptor 120 and a second interface 170 for connecting adaptor 120 to gage pallet 140. First interface 160 and second interface 170 are similar to those described above for FIGS. 3A to 3C.
Workpiece retaining member 102 comprises a workpiece retaining member portion 118 and a workpiece retaining member interface portion 128. Workpiece retaining member portion 118 comprises at least one workpiece retaining member surface 138 for securely holding a workpiece. FIGS. 4 and 5 illustrate a cube shaped workpiece retaining member portion capable of retaining four workpieces. Workpiece retaining member interface portion 128 includes interface surface 162.
First interface 160 provides a standardized operable connection between a workpiece retaining member interface surface 162 of workpiece retaining member 102 and adapter interface surface 126 of adaptor 120.
Workpiece retaining member interface portion 128 includes a flange portion 114 with one or more apertures 116 formed therein for receiving a like number of retaining members (e.g., bolts, clips, and the like). Adaptor interface surface 126 includes one or more apertures 122 formed therein, some of which correspond to apertures 116 for receiving a like number of retaining members and providing operable attachment to the workpiece retaining member 102.
Adaptor 120 includes one or more pins 124 projecting from first adaptor interface surface 126 to provide means for aligning the workpiece retaining member 102 relative to adaptor 120.
Adaptor 120 may include hydraulically- and/or pneumatically-actuated means for facilitating the alignment and/or interchanging of workpiece retaining members. FIG. 4 illustrates that adaptor 120 includes one or more hydraulic members 110 and one or more pneumatic members 112 for providing positioning of workpiece retaining member 102 relative to adaptor 120. Hydraulic couplings 111 may provide means for operably attaching hydraulic lines to the hydraulic members 110 for supplying pressurized hydraulic fluid. Air couplings 113 may provide means for operably attaching air lines to the pneumatic members 112 for supplying pressurized air.
FIG. 5 shows workpieces 104 attached to workpiece retaining member portion 118. In this embodiment, workpieces 104 are secured to workpiece retaining member portion 118 via hydraulically actuated clamps 130. Hydraulically actuated clamps 130 are in fluid communication with hydraulic lines connected to the adaptor 120 via hydraulic couplings 111. The hydraulic couplings 111 may be the same or similar to hydraulic couplings 74 discussed above and illustrated in FIG. 3A. Prior to clamping the workpiece 104 to the workpiece retaining member portion surface 138, the workpiece must be properly positioned. Workpiece 104 may be properly positioned on workpiece retaining member surface 138 by using a crowder arm assembly 132, a locator assembly 134 or any other means or combination of means known in the art.
In another embodiment, pneumatic means are used to secure workpieces 104. FIG. 6 shows workpieces 104 attached to workpiece retaining member portion 118. In this embodiment, workpieces 104 are secured to workpiece retaining member portion 118 via pneumatically actuated clamps 136. Pneumatically actuated clamps 136 are in fluid communication with air lines connected to the adaptor 120 via air couplings 113. Air couplings 113 may be the same or similar to air couplings 76 discussed above and illustrated in FIG. 3A.
Gage pallet 140 of a machining center supports workpiece retaining member 102 through the adaptor 120, which is affixed to the gage pallet 140 and positioned substantially between the workpiece retaining member 102 and the gage pallet 140. Gage pallet 140 is specific to a particular brand or type of machining center. Second interface 170 provides a customized operable connecting interface between adaptor 120 and gage pallet 140. Adaptor 120 includes a second adaptor interface surface 127 that corresponds to a particular gage pallet interface surface 152 of gage pallet 140.
Gage pallet interface surface 152 includes a plurality of reference slots having a cross-sectional shape of an inverted T (hereinafter referred to as T-slots 150), which are substantially parallel and formed within surface 152. T-slots 150 extend along one direction from one edge of the gage pallet 140 to another edge and correspond to apertures 122 of adaptor 120. Apertures 122 and the T-slots 150 may receive a like number of retaining members (e.g., bolts, clips, and the like) for fixedly attaching the adaptor 120 to the gage pallet 140.
In one embodiment, gage pallet 140 is supported by a rotary table 142, which includes one or more projections 144 formed on its top surface 146. Projections 144 correspond to apertures formed on a bottom surface 148 of gage pallet 140 thereby providing appropriate alignment between rotary table 142 and gage pallet 140.
It should be appreciated that the adaptor 120 and gage pallet 140 are not limited to having interface surfaces that are as illustrated and described herein. Indeed, the formation of the interface surfaces within the gage pallet top surface may vary from manufacturer to manufacturer, sometimes in a proprietary manner thereby necessitating the customized interface as described above. As such, the number, position, size, geometry, and type of apertures and slots, hydraulic and
pneumatic connections and the like may be designed to provide operable connection of the machine fixture assembly components, one to another.
Referring now to FIGS. 7 A, 7B, and 7C, schematic views illustrating a method of interchanging two different workpiece retaining members to a standardized adaptor interface in a machining fixture assembly 100 are provided, in accordance with one embodiment of the present invention. As shown in FIG. 7 A, adaptor 120 is positioned substantially between a first workpiece retaining member 102a and gage pallet 140. First workpiece retaining member 102a includes a standardized workpiece retaining member interface surface that corresponds to a standardized adaptor interface surface of adaptor 120 as described above for FIGS 2 to 6. First workpiece retaining member 102a, which is generally locked to the adaptor 120, may be unlocked by releasing locking members 42. First workpiece retaining member 102a is removed from adaptor 120 with the assistance of at least one of the pneumatic members 110 and/or hydraulic members 112 leaving adaptor 120 attached to the gage pallet as shown in FIG. 7B via a customized interface as described above. Hydraulic members 110 and/or pneumatic members 112 provide an upward force to at least assist removal of the first workpiece retaining member 102a from adaptor 120.
A second workpiece retaining member 102b, having a standardized workpiece retaining member interface surface, is then moved into place and positioned, which includes lifting and lowering, onto adaptor 120 with the assistance of at least one of the hydraulic 110 and pneumatic 112 members. During the positioning process, pins provided on the surfaces of adaptor 120 and/or the second workpiece retaining member 102b may facilitate the process and ensure proper alignment. Once lowered, the second workpiece retaining member 102b is operably attached to adaptor 120 with retaining members positioned through the apertures of the second workpiece retaining member 102b and adaptor 120. In addition, locking members 42 may be engaged to retain the second workpiece retaining member 102b to adaptor 120.
In another embodiment, it may be desirable to also interchange the adaptor 120 as well as the first workpiece retaining member 102a. This may be accomplished by removing the adaptor 120 from the gage pallet 140 after the removal of the first workpiece retaining member 102a. Adaptor 120 maybe exchanged with another adaptor, which is then operably attached to the gage pallet 140. Second workpiece retaining member 102b may then be lowered onto the exchanged adaptor and operably attached as previously discussed. This embodiment would provide a desirable alternative for attaching a two or more workpiece retaining members with different interface designs to a given pallet.
In yet another embodiment (not shown), the workpiece retaining member and adaptor may be removed as one unit from the gage pallet. The adaptor may be removed from the workpiece retaining member and exchange for a second adaptor. Workpiece retaining unit and second adaptor may then be positioned, aligned, and locked onto a second gage pallet.
FIG.8 shows a manufacturing system 300 incorporating a machining fixture system
20 in accordance with the present invention. Manufacturing system 300 includes a machining center 310, and a conveyor system 310 for transporting machining fixture system 20 between a first location outside a work envelope of the machining center and a second location within the work envelope of the machining center. Machining center may comprise a multi¬ function machine including such features as three or more axes of motion, a contouring-type numerical control, and/or an automatic tool changer. Conveyor system 320 may include a roller conveyor that is retractable and/or foldable, as known in the art. A retractable conveyor may be relatively easily moved away from the machining center when not in use. When machining fixture system 20 is withdrawn from the work envelope of machining center 310, a first workpiece retaining member coupled to machining fixture system 20 may be rapidly changed over to a second workpiece retaining member, as previously described.
While the embodiments of the invention disclosed herein are presently considered to be preferred, various changes and modifications may be made without departing from the spirit and scope of the present invention. For example, the machining assembly, adaptor, and method of interchanging the machining assembly are not limited to any particular design, configuration, sequence, or arrangement. The workpiece retaining member, adaptor, gage pallet, and associated components may vary in shape, geometry, location, orientation, number, and function without limiting the utility of the invention. Furthermore, the method may be accomplished by numerous alternative strategies and may include additional or modifications to the described steps.
Upon reading (he specification and reviewing the drawings hereof, it will become immediately obvious to those skilled in the art that myriad other embodiments of the present invention are possible, and that such embodiments are contemplated and fall within the scope of the presently claimed invention. The scope of the invention is indicated in the appended claims, and all changes that come within the meaning and range of equivalents are intended to be embraced therein.