Process for assembling different categories of multi-element assemblies to predetermined tolerances and alignments using a reconifigurable assembling and alignment apparatus

Patent metadata

Field	Value
Publication number	US-9647343-B2
Application number	US-201614992456-A
Country	US
Kind code	B2
Filing date	Jan 11, 2016
Priority date	Jan 8, 2014
Publication date	May 9, 2017
Grant date	May 9, 2017

Abstract

Systems and methods for assembling different multi-element items with different specifications using a reconfigurable apparatus are provided. One embodiment includes a base plate, a back plate coupled to the base plate in a predetermined angle relationship. The exemplary back plate comprises a plurality of alignment pins adapted to engage with alignment locations of multiple element assembly items. The exemplary base plate and alignment mounting structures couple to end cap parts disposed on opposing ends of the multiple element assembly items holding the items together. A clamping mechanism maintains/releases pressure on the multiple element assembly items against the back plate. The back plate holds alignment pins in a first back plate location in a first orientation for one type of multiple element assembly items and hold the alignment pins in a second location when the back plate is in a second orientation for a different type of multiple element assembly items.

First claim

The invention claimed is:

1. A method for assembling a multi-element apparatus using a reconfigurable assembly apparatus comprising:
providing an assembly/alignment structure comprising a base plate comprising a mounting surface and at least one mounting structures on an edge of said mounting surface comprising at least one first mounting holes; a back plate comprising an at least one second mounting holes adapted to couple with said first mounting holes, an at least one elongated aperture running across said back plate at a first predetermined distance from a first edge of said back plate and a second predetermined distance from a second edge of said back plate, an at least one mounting bolts adapted to couple said base plate and said back plate through said first and second mounting holes, a plurality of alignment pins adapted to insert into or through said at least one aperture; an alignment structure comprising a structure that couples with said base plate to provide a support surface a third predetermined distance from said base plate; and an at least one compression or clamping mechanism comprising a plurality of protrusions from a first and second section of said compression or clamping mechanism, wherein said first predetermined distance is associated with alignment characteristics of a first plurality of directional elements and said second predetermined distance is associated with alignment characteristics of a second plurality of directional elements;
providing said plurality of first directional elements adapted to have at least one directional characteristic having a directional axis associated with at least one electromagnetic signal receiving aspect of each of the elements, each of said plurality of first directional elements comprising a first section, a second section and a third section, wherein said first section comprises an at least one connector hole adapted to receive a protrusive structure and said second section formed with a rod passage through said second section such that each of said plurality of first directional elements rod passages align with each other when said plurality of first directional elements are coupled together, and said third section comprises a section formed in three wall sections so as to create a plurality of directional openings on one side of said stack when said plurality of first directional elements are coupled together, wherein each of said directional openings is formed to have a relationship with said directional axis;
providing a first and second end caps each adapted to couple to one of said plurality of first directional elements positioned at either end of a stack of said plurality of first directional elements, an at least one threaded rods configured to pass through said rod passages and coupled said plurality of first directional elements together, and at least one set of first and second rod nuts configured to couple to said threaded rods and apply compressive force between said first and second nuts to said plurality of first directional elements, an at least one bolt, an at least one connector, an at least one shim configured to alter alignment of one or more said plurality of first directional elements when they are coupled to form said stack so as to adjust said first directional elements to align each of said first directional elements' directional axis;
positioning said back plate in a first orientation so as to align said base plate's said at least one first mounting holes with corresponding said back plate's at least one second mounting holes, so that said back plate's elongated aperture adapted to receive said plurality of alignment pins is in position to each enable respective alignment and insertion of said pins into said connector holes in said first section of each of said plurality of first directional elements;
inserting said plurality of alignment pins through said back plate elongated aperture;
installing said first and second end cap with said end cap mounting bolts to said base plate;
sequentially positioning and coupling each of said plurality of first directional elements between said first and second end caps on said base plate by sequentially placing one side of said plurality of first directional elements on said base plate and said first section of said plurality of first directional elements on said base plate so as to bring said first section of each said directional element in contact with said back plate and aligning said connector hole with a respective one of said plurality of alignment pins such that each said directional axis of each of said plurality of first directional elements are approximately parallel to each other and aligned in at least two reference planes;
installing said end caps on either end of said plurality of directional element's stack;
inserting said plurality of protrusions extending from said compression or clamping mechanism into at least some of said plurality of directional openings on opposing end sections of said stack of said plurality of directional element stack;
applying compressive pressure to said element stack using said compression or clamping mechanism;
installing said at least one threaded rods into said rod passages and coupling said first and second nuts on said at least one threaded rod;
applying predetermined final torque on installed said at least one threaded rods;
making at least one alignment measurement of said stack and said plurality of first directional elements to determine one or more out of alignment parameters exists associated with one or more said directional axis of one or more said plurality of first directional elements exists, wherein said one or more out of alignment parameters comprise an out of parallel dimension range parameter associated with said plurality of first directional elements;
if said out of parallel dimension range or parameter condition exists, determining size and number of said shims to bring said plurality of first directional elements into a predetermined alignment associated with said first directional axis of each said first directional elements;
making adjustment of one or more said first directional elements by loosening said nuts and said compressive or clamping structure's pressure on said first directional element stack sufficient to enable insertion of said shims into said first directional element stack so as to bring said stack into said predetermined alignment;
tightening said compression or clamping mechanism and said first and second nuts on said at least one threaded rods, using a predetermined torque pattern;
repeating said making at least one alignment measurement step to determine said one or more out of alignment parameters exists and repeating steps following said making at least one alignment measurement step until said one or more alignment parameters are not found to exist.

2. A method of claim 1 , wherein said first directional element item is a horn antenna.

3. A method of claim 1 , wherein said element item is a directional radio frequency antenna.

4. A method of claim 1 , wherein said compression or clamping mechanism comprises a scissor jack that has a threaded axle which extends or retracts the jack and that is placed between two said wood structures.

5. A method of claim 1 , wherein said compression or clamping mechanism comprises a ratchet strap.

6. A method of claim 1 , wherein said compression or clamping mechanism's plurality of protrusions comprises at least one finger bracket.

Assignees

• Us Navy

Inventors

• Waters Jeffrey M

Classifications

• H01Q21/064

  using horn or slot aerials (slotted waveguides arrays H01Q21/005) · CPC title

• Y10T29/49899

  by multiple cooperating aligning means · CPC title

• Y10T29/49016

  Antenna or wave energy "plumbing" making · CPC title

• H01Q1/1207

  for fastening a rigid aerial element · CPC title

• Y10T29/4902

  Electromagnet, transformer or inductor · CPC title