Abstract:
The modular fixturing system of the present invention is modular, reusable and capable of significant customization, both in terms of system radius and system height, allowing it to be arranged and rearranged in numerous unique configurations. The system includes multiple modular stanchions having stanchion shafts and stanchion feet that removably attach to apertures in a table. Angle brackets attached to the modular stanchions support shelves. These shelves in turn provide support to work pieces during fabrication processes such as welding.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     The invention described herein was made by an employee of the United States Government and may be manufactured and used by the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     This invention relates to the field of metal fabrication and more specifically to a fixturing system capable of holding components in place for large-scale fabrication projects. 
     2. Description of Related Art 
     NASA and the aerospace industry require highly specialized equipment for the fabrication of rockets and other aerospace vehicles. These projects require assembly and manipulation of large components with very low error tolerance. For example, in 2014, NASA developed a specialized Vertical Assembly Center to construct the 200-foot-tall core stage for a massive rocket designed for extended manned missions. 
     Welding and fabrication processes require the use of frameworks to secure rocket components in place during fabrication. Currently, large-scale fixturing systems known in the art are constructed from stationary pipes and rods, which are joined to form a framework. Movable components referred to as shoes extend from the pipes and rods to provide for precise positional adjustments. When fabrication is complete, this framework must be disassembled or stored using large amounts of storage space. 
     Reusable fixturing systems known in the art cannot withstand the heavy loads or meet stress requirements necessary for rocket fabrication. The use of easily disassembled modular components introduces unacceptable error to the assembly process due to deformation and misalignment of components during assembly. Misalignment may not be visible during fabrication, but can render a finished object unusable. 
     There is an unmet need in the art for a modular fixturing system capable of accommodating large-scale fabrication projects, such as rockets and other spacecraft. 
     SUMMARY OF THE INVENTION 
     The present invention is a novel modular stanchion system constructed using a plurality of stanchions, shelves and brackets in place of pipes and rods. Each modular stanchion includes a stanchion shaft connected to at least one stanchion foot. This stanchion foot connects to an aperture in a table. The stanchion shaft has apertures used to connect objects to the stanchion and to connect the stanchion to other objects. Angle brackets connect to the modular stanchions, and shelves connect to the angle brackets. Each of the angle brackets includes a bracket platform component and an upright component. The bracket platform and upright components include apertures. The shelves have a substantially planar configuration. Each of the shelves includes apertures. Fasteners extend through the stanchion, bracket and shelf apertures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1 a -1 c    illustrate perspective views of first and second configurations and a partial side view of the second configuration, respectively, of an exemplary embodiment of a modular stanchion system (MSS). 
         FIGS. 2 a  and 2 b    illustrate side and partial top views, respectively, of an exemplary embodiment of a modular stanchion with an optional fixed angle support. 
         FIG. 2 c    illustrates a side view of an exemplary embodiment of a modular stanchion with an optional adjustable angle support. 
         FIG. 2 d    illustrates a perspective view of an exemplary embodiment of a stanchion extension. 
         FIG. 3  illustrates a perspective view of an exemplary embodiment of a turnbuckle. 
         FIGS. 4 a  and 4 b    illustrate top and perspective views, respectively, of an exemplary embodiment of a knuckle. 
         FIGS. 5 a -5 c    illustrate front, side and perspective views, respectively, of an exemplary embodiment of an angle bracket. 
         FIGS. 6 a -6 c    illustrate top, front and perspective views, respectively, of an exemplary embodiment of a shelf, while  FIG. 6 d    illustrates a front view of an exemplary embodiment of the shelf mounted to angle brackets. 
         FIGS. 7 a -7 c    illustrate perspective, exploded and top views, respectively, of an exemplary embodiment of a shoe assembly. 
     
    
    
     TERMS OF ART 
     As used herein, the term “angle bracket” means a substantially right-angled support attached to and projecting from a surface having a vertical component. 
     As used herein, the term “brace” means an optional support attachment. 
     As used herein, the term “cap” means a component connected to a stanchion shaft and contacting a component being fabricated. 
     As used herein, the term “clevis” means a substantially U-shaped connector within which another part can be fastened by means of a pin passing through apertures in the connector. 
     As used herein, the term “foot” means a component capable of connecting to a stanchion shaft and a table. 
     As used herein, the term “knuckle” means a joint capable of rotation in at least one direction. 
     As used herein, the term “modular” means capable of being selectively attached, removed or changed. 
     As used herein, the term “rotatably” means capable of revolving around an axis. 
     As used herein, the term “shaft” means the primary portion of a stanchion that extends at least partially vertically. 
     As used herein, the term “stanchion” means a bar or post assembly extending at least partially vertically. 
     As used herein, the term “table” means a component or base to which one or more modular stanchions are secured. 
     As used herein, the term “turnbuckle” means a coupling using a threaded connection to adjust the tension or distance between two points. 
     DETAILED DESCRIPTION 
       FIGS. 1 a -1 c    illustrate perspective views of first and second configurations and a partial side view of the second configuration, respectively, of an exemplary embodiment of MSS  100 . MSS  100  mounts to a table  10  having a plurality of table apertures  11 . In the exemplary embodiment, table  10  is a round turntable. In other embodiments, table  10  is a fixed rectangular table, fixed round table or rectangular turntable. In the exemplary embodiment, table apertures  11  are elongated slots. In other embodiments, table apertures  11  are round, square or rectangular apertures. 
     MSS  100  includes a plurality of modular stanchions  20 , a plurality of optional stanchion braces  30 , a plurality of optional turnbuckles  40 , a plurality of optional knuckles  50 , a plurality of angle brackets  60 , a plurality of shelves  70 , a plurality of optional shoe assemblies  80  and a plurality of fasteners  95 . Modular stanchions  20  and stanchion braces  30  connect to table apertures  11 . Knuckles  50  connect stanchion braces  30  and turnbuckles  40  to modular stanchions  20 . Angle brackets  60  connect shelves  70  to modular stanchions  20 . Shelves  70  support shoe assemblies  80 . Fasteners  95  connect knuckles  50  and angle brackets  60  to modular stanchions  20 , angle brackets  60  to shelves  70 , and shelves  70  to shoe assemblies  80 . Stanchion braces  30  provide additional reinforcement against forces exerted on MSS  100 . 
       FIGS. 2 a  and 2 b    illustrate side and partial top views, respectively, of an exemplary embodiment of modular stanchion  20  with optional fixed angle support  26 . Modular stanchions  20  provide significant load-bearing capabilities to MSS  100  and serve to interconnect other components of MSS  100  with table  10 . Repositioning modular stanchions  20  on table  10  allows for gross adjustment of the overall radius of MSS  100 . 
     In this embodiment, modular stanchion  20  includes a stanchion shaft  21 , at least one stanchion foot  22 , a plurality of stanchion attachment apertures  23 , at least one optional stanchion tracker  24 , a plurality of optional stanchion dowel apertures  25 , a fixed angle support  26  and an optional stanchion cap  29 . Stanchion shaft  21  is a vertical shaft with a rectangular cross-section fixedly mounted to stanchion foot  22 . Stanchion shaft  21  has a length ranging from approximately 1 foot to approximately 50 feet. Stanchion foot  22  connects to at least one table aperture  11  to adjustably position modular stanchion  20  on table  10 . In the exemplary embodiment, both stanchion shaft  21  and fixed angle support  26  mount to the same stanchion foot  22 . In other embodiments, stanchion shaft  21  and fixed angle support  26  each mount to their own stanchion foot  22 . 
     Stanchion shaft  21  also includes stanchion attachment apertures  23  on at least one side. In the exemplary embodiment, stanchion attachment apertures  23  are located on all four sides and the upper surface of stanchion shaft  21 . In the exemplary embodiment, stanchion attachment apertures  23  form multiple groupings, each grouping made up of four stanchion attachment apertures  23  arranged in a substantially square pattern. The spacing of these groupings accommodates complementary apertures in knuckles  50  and angle brackets  60 . Other components may also attach to stanchion shaft  21  using stanchion attachment apertures  23 . 
     In the exemplary embodiment, stanchion shaft  21  also includes stanchion tracker  24 , a laser tracker hole located on the upper surface of stanchion shaft  21 . When moving modular stanchion  20  into position on table  10 , stanchion tracker  24  allows a user to determine when modular stanchion  20  reaches the correct position. All modular stanchions  20  within MSS  10  have stanchion trackers  24  in the same location to ensure uniform positioning. In the exemplary embodiment, stanchion shaft  21  also includes stanchion dowel apertures  25 . Stanchion dowel apertures  25  receive dowels that peg to complementary apertures in angle brackets  60  to accurately locate angle bracket  60  during attachment. 
     Fixed angle support  26  is an angled shaft fixed between stanchion shaft  21  and stanchion foot  22 . When stanchion shaft  21  experiences angled or horizontal forces, fixed angle support  26  provides reinforcement. Fixed angle support  26  has a rectangular, square or round cross-section and forms an angle with stanchion foot  22  ranging from approximately 15 degrees to approximately 90 degrees. 
     Stanchion cap  29  is an aluminum block with an upper surface that supports work pieces during assembly and fabrication. This upper surface may be stepped, angled or flat. Stanchion cap  29  removably connects to the upper surface of stanchion shaft  21 . 
       FIG. 2 c    illustrates a side view of an exemplary embodiment of modular stanchion  20  with optional adjustable angle support  27 . In this embodiment, modular stanchion  20  includes a stanchion shaft  21 , two stanchion feet  22   a  and  22   b , stanchion attachment apertures  23  and an adjustable angle support  27 . The structure and function of stanchion attachment apertures  23  is substantially identical to those of the embodiment of  FIGS. 2 a  and 2 b    above. 
     In this embodiment, stanchion shaft  21  is a vertical shaft with a rectangular cross-section rotatably connected to stanchion foot  22   a  and adjustable angle support  27 . In this embodiment, stanchion shaft  21  and adjustable angle support  27  each rotatably connect to their own stanchion foot  22   a  and  22   b , respectively. Stanchion feet  22   a  and  22   b  connect to table aperture  11  to adjustably position modular stanchion  20  on table  10 . The distance between stanchion foot  22   a  and  22   b  determines the relative angle between stanchion shaft  21  and adjustable angle support  27 , as well as the angulation of stanchion shaft  21 . Stanchion shaft  21  forms an angle with stanchion foot  22   a  ranging from approximately 15 degrees to approximately 90 degrees. 
       FIG. 2 d    illustrates a perspective view of an exemplary embodiment of stanchion extension  28 . Stanchion extension  28  is a vertical shaft with a rectangular cross-section removably mounted to the upper surface of stanchion shaft  21  using stanchion attachment apertures  23 . A user increases the overall height of stanchion shaft  21  by removably connecting at least one stanchion extension  28 . In cases where additional height increase is necessary, one or more additional stanchion extensions  28  may connect to the first stanchion extension  28 . The cross-section of stanchion extension  28  matches that of stanchion shaft  21 . Each stanchion extension  28  has a height ranging from approximately 1 foot to approximately 50 feet. 
     Stanchion extension  28  also includes a plurality of stanchion attachment apertures  23 . In the exemplary embodiment, stanchion attachment apertures  23  are located on all four sides and the upper and lower surfaces of stanchion extension  28 . In the exemplary embodiment, stanchion attachment apertures  23  form multiple groupings, each grouping made up of four stanchion attachment apertures  23  arranged in a square pattern. The spacing of these groupings accommodates complementary apertures in stanchion shaft  21 , other stanchion extensions  28 , knuckles  50  and angle brackets  60 . 
       FIG. 3  illustrates a perspective view of an exemplary embodiment of turnbuckle  40 . Turnbuckle  40  provides optional added stabilization between various elements of MSS  100 . By way of non-limiting example, fixing turnbuckle  40  between two modular stanchions  20  provides resistance to lateral relative movement in modular stanchions  20 . 
     Turnbuckle  40  includes a turnbuckle adjustment frame  41 , two turnbuckle nuts  42   a  and  42   b , and two turnbuckle eyebolts  43   a  and  43   b . Turnbuckle adjustment frame  41  is a hollow cylinder having turnbuckle nuts  42   a  and  42   b  connected to either end. The threaded shank of each turnbuckle eyebolt  43   a  and  43   b  rotatably connects to turnbuckle nuts  42   a  and  42   b , respectively. Rotation of turnbuckle eyebolts  43   a  and  43   b  relative to turnbuckle adjustment frame  41 , or vice versa, serves to expand and contract the overall length of turnbuckle  40 . The eye of each turnbuckle eyebolt  43   a  and  43   b  removably connects to one of knuckles  50 . 
       FIGS. 4 a  and 4 b    illustrate top and perspective views, respectively, of an exemplary embodiment of knuckle  50 . Knuckle  50  optionally provides a highly modular connection between elements of MSS  100 . Each knuckle  50  includes a knuckle base  51 , a plurality of knuckle attachment apertures  52 , a knuckle swivel  53 , a knuckle clevis  54 , a plurality of knuckle clevis pin apertures  55 , a knuckle clevis pin  56  and a knuckle clevis pin lock  57 . Knuckle base  51  removably connects to stanchion shaft  21  by means of fasteners  95  inserted through stanchion attachment apertures  23  and knuckle attachment apertures  52 . In the exemplary embodiment, knuckle base  51  includes eight knuckle attachment apertures  52  arranged at 45-degree increments in a substantially circular pattern, allowing orientation and positioning of knuckle  50  in 45-degree increments relative to stanchion shaft  21 . 
     Knuckle swivel  53  rotatably connects knuckle base  51  to knuckle clevis  54 . Knuckle swivel  53  can rotate through 360 degrees. Knuckle clevis  54  receives turnbuckle eyebolt  43   a  or  43   b  between knuckle clevis pin apertures  55 . Insertion of knuckle clevis pin  56  through eyebolt  43   a  or  43   b  and knuckle clevis pin apertures  55  removably connects turnbuckle  40  and knuckle  50 . Insertion of knuckle clevis pin lock  57  through knuckle clevis pin  56  removably locks knuckle clevis pin  56  in place, preventing accidental dislodgment. 
       FIGS. 5 a -5 c    illustrate front, side and perspective views, respectively, of an exemplary embodiment of angle bracket  60 . Angle bracket  60  removably connects shelf  70  to modular stanchion  20 . Angle bracket  60  has a substantially upside-down L-shaped configuration. Angle bracket  60  includes a bracket platform  61 , a bracket upright  62 , a bracket support  63 , a plurality of bracket attachment apertures  64  and a plurality of bracket dowel apertures  65 . Bracket platform  61  removably connects to shelf  70 , while bracket upright  62  removably connects to modular stanchion  20 . In the exemplary embodiment, bracket platform  61  supports lateral sides of two different shelves  70 . Bracket support  63  extends between bracket platform  61  and bracket upright  62  to provide additional support to bracket platform  61 . 
     In the exemplary embodiment, bracket attachment apertures  64  are located in both bracket platform  61  and bracket upright  62 . In the exemplary embodiment, bracket attachment apertures  64  in bracket upright  62  have an elongated configuration. This configuration allows highly adjustable positioning of angle bracket  60  with respect to modular stanchion  20 . In the exemplary embodiment, bracket dowel apertures  65  are located in bracket upright  62 . Bracket dowel apertures  65  receive dowels that peg to complementary stanchion dowel apertures  25  to accurately locate angle bracket  60  during attachment to modular stanchion  20 . 
       FIGS. 6 a -6 c    illustrate top, front and perspective views, respectively, of an exemplary embodiment of shelf  70 . Shelf  70  has a substantially planar configuration and is manufactured from metallic materials such as, but not limited to aluminum. In the exemplary embodiment, shelf  70  has a planar, partially curved rectangular configuration. The configuration of shelves  70  allows incremental alterations to MSS  100  diameter. 
     Shelf  70  supports shoe assembly  80  and connects shoe assembly  80  to modular stanchion  20 . Shelf  70  includes a plurality of shelf attachment apertures  71  and at least one optional shelf tracker  72 . Bracket platform  61  removably connects to a lower surface of shelf  70  through shelf attachment apertures  71 . In the exemplary embodiment, two bracket platforms  61  support each shelf  70  through shelf attachment apertures  71  located on lateral sides of shelf  70 . Other embodiments add one or more additional bracket platforms  61  to support each shelf  70  depending on the overall length of and support required for each shelf  70 . 
     In the exemplary embodiment, shelf trackers  72  are laser tracker holes located on the upper surface of shelf  70  and the front surface of shelf  70 . When connecting shelf  70  to modular stanchion  20 , shelf trackers  72  allow a user to determine when shelf  70  reaches the correct height on modular stanchion  20  and position above table  10 . In other embodiments, shelf  70  includes only a single shelf tracker  72 . 
       FIGS. 7 a -7 c    illustrate perspective, exploded and top views, respectively, of an exemplary embodiment of shoe assembly  80 . Shoe assembly  80  supports and rounds the work piece, allowing for fine adjustment of the overall radius of MSS  100 . Shoe assembly  80  translates manufacturing loads placed on work pieces into MSS  100  while maintaining dimensional tolerances during fabrication. Shoe assembly  80  includes an optional shoe platform  81 , a shoe frame  82 , a shoe  83 , two optional shoe grooves  84   a  and  84   b , an optional shoe backplate  85 , two optional shoe set screws  86   a  and  86   b , a plurality of optional shoe attachment apertures  87 , a threaded rod  90 , an optional threaded rod aperture  91  and an optional rod set screw  92 . 
     Shoe platform  81  is a removable separator between shoe frame  82  and shelf  70  having a substantially wedge-shaped configuration. When used, shoe platform  81  angles shoe frame  82  relative to shelf  70 . This angulation may range from approximately one degree to approximately 45 degrees. Shoe frame  82  has a u-shaped cross-section. Shoe  83  has a box-shaped configuration with a rounded front surface. In the exemplary embodiment, the rounded front surface of shoe  83  has a radius of approximately 0.25 inches. Other embodiments may have a radius of up to one inch. In the exemplary embodiment, shoe  83  is made from aluminum. Optionally, shoe  83  can slidably connect to shoe frame  82  through shoe grooves  84   a  and  84   b  in the inner lateral sides of shoe frame  82  for additional guidance during use. 
     Shoe backplate  85  can close off the rear of shoe frame  82 . Shoe backplate  85  connects across the rear of shoe frame  82 , with shoe set screws  86   a  and  86   b  extending through shoe backplate  85  and into shoe frame  82 . In the exemplary embodiment, fasteners  95  extend through shoe attachment apertures  87  to removably connect shoe frame  82  to shelf  70 . In other embodiments, shoe assembly  80  is an integrated part of shelf  70 . 
     The front end of threaded rod  90  extends within shoe  83 , allowing shoe  83  to extend from and retract into shoe frame  82  by movement of threaded rod  90 . In the exemplary embodiment, the configuration of the back end of threaded rod  90  can be, but is not limited to, a substantially recessed, square, pentagonal or hexagonal cross-section. This allows removable connection to manual or powered drivers, such as, but not limited to a hand tool, drill or motor. 
     In the exemplary embodiment, threaded rod  90  extends through threaded rod aperture  91  in shoe backplate  85 . Threaded rod aperture  91  has an internal threading that substantially corresponds to the external threading of threaded rod  90 , allowing guided extension and retraction of threaded rod  90  through threaded rod aperture  91 . In the exemplary embodiment, rod set screw  92  holds threaded rod  90  in place within shoe  83 . In use, rotation of threaded rod  90  to extend shoe  83  pushes on shoe  83 , not rod set screw  92 . 
     Fasteners  95  are standardized bolts having identical gauge and thread density (threads per inch). In the exemplary embodiment, fasteners  95  are bolts with a diameter of approximately 0.5 inches and a thread density of approximately 13. 
     It will be understood that many additional changes in the details, materials, procedures and arrangement of parts, which have been herein described and illustrated to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. 
     It should be further understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention. Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related.