Abstract:
The present invention provides novel approaches to manufacturing and assembling linear motion slides that are quick and easy to install without requiring the use of fasteners. Additionally, the present invention discloses a novel track assembly apparatus that couples with standard linear motion support bases without the use of fasteners.

Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The invention relates generally to methods and apparatus for assembling a linear track in a guided motion system. In particular, the invention relates to a track assembly that supports a quick and easy method of assembly of linear tracks to standard extrusions. 
     2. Description of the Prior Art 
     In manufacturing processes and within manufactured capital goods themselves, precise and repeatable motion is useful and often essential. For example, in manufacturing processes ranging from machining to textiles to electronics, tool heads or other items move back and forth and must do so precisely and repeatedly over enormous numbers of cycles. In another example, specimens and instrumentation move relative to each other within laboratory analytic devices to collect data on the samples and must do so precisely and repeatedly. 
     Guide wheels attached to support bases and riding on rails is one class of guided motion technology that provides precise and repeatable kinematics. For example, U.S. Pat. No. 3,661,431 discloses guide wheels and tracks in which guide wheels cooperate with rails such that the guide wheels may move along the rails. 
     An exemplary track used in guided motion application is shown in  FIG. 1 .  FIG. 1  illustrates an exploded view of a guided motion apparatus  100  as known in the prior art.  FIG. 1  shows a “Vee” edge track  120  and the DualVee® guide wheel  110  both manufactured by Bishop-Wisecarver Corporation. The track  120  is coupled with a support base (aka extrusion)  130 . 
     Known support bases are typically available in a standard size and configuration. For example, the extrusion  130  shown in  FIG. 1  is a representation of a standard aluminum extrusion support base manufactured by Parker Hannifin Corporation which is widely used within the guided motion industry. 
     Also widely used in the guided motion industry are track assemblies for coupling the track with the support base.  FIG. 1  illustrates a known track assembly  125  for coupling the “Vee” edge track  120  to a standard extrusion  130 . Previous attempts to provide track assemblies to fit standard support bases have been complicated, time consuming, difficult to assemble due to the requirement of fasteners, expensive to assemble, and unreliable due to the use of moving parts, among other shortcomings. However, there are many disadvantages to the current state of the art. For example, known track assemblies require the use of fasteners (not shown) to couple the track assembly  125  and the track  120 . Requiring the use of fasteners necessitates more parts, a more expensive manufacturing process, more susceptibility to movement between the parts, resulting in an unsatisfactory guided motion apparatus which requires a finely tuned system. 
     Due to the deficiencies of the prior art, there is a need to provide a reliable, effective and easy to assemble track assembly for use with linear motion support bases. Therefore, it is an object of the present invention to provide a track assembly that effectively couples with a standard support base without the use of fasteners. 
     It is another object of the invention to provide methods of manufacturing track assemblies that effectively couple with a standard support base without the use of fasteners. Additionally, it is an object of the invention to provide methods of assembling guided motion systems using fastener-less assembly techniques. 
     SUMMARY OF THE INVENTION 
     The present invention provides novel approaches to manufacturing and assembling linear motion slides that are quick and easy to install without requiring the use of fasteners. Furthermore, the present invention discloses a novel track assembly apparatus that couples with standard linear motion support bases without the use of fasteners. 
     The elimination of fasteners results in lower cost, faster assembly, and increased structural integrity due to the elimination of drill holes and/or tapped holes in the track. According to some embodiments of the present invention, traditional fasteners are replaced with deformable teeth protrusions. 
     It is an object of the present invention to utilize track clamps having a pressure insert portion with teeth protrusions that deform upon coupling with the support base. The deformation of the track clamp teeth ensures a tight fit without the use of fasteners. 
     Various embodiments of the present invention include track assemblies designed to couple tracks to support bases in a variety of configurations including tracks disposed normal to the support base and tracks disposed orthogonal to the support base. In some embodiments of the present invention, the track clamps are designed with shoulder extensions to provide extra support withstand torque on the track. 
     In some embodiments of the present invention, the track clamp apparatus is especially designed to suit any slot in a wide variety of extrusions or barstock material. In the preferred embodiment of the present invention, the track clamp enables the user to integrate the “Vee” edge track manufactured by Bishop-Wisecarver Corporation into the T-slots of standard structural extrusion support bases. 
     Some embodiments of the present invention teach low cost methods of installing linear motion tracks into structural extrusion support bases. In some embodiments, the novel track clamp is simply installed using a soft-headed mallet. In some other embodiments, the track is able to be installed by using a cross-head arrangement of rollers to uniformly apply force to insert the track clamp and track into standard structural extrusion support bases. In some embodiments, the track clamp and track are assembled in a factory. In some other embodiments, the track and track clamp are assembled by an end user. 
     In some embodiments of the present invention, the track clamps are integrated with widely available standard aluminum extrusion support bases such as those manufactured by Parker Hannifin Corporation. In some embodiments of the present invention, the track clamps are especially designed to accommodate various sized “Vee” edge tracks manufactured by Bishop-Wisecarver Corporation. For example, the track clamp is designed for tracks sized 0 thru 4, in carbon steel. In some embodiments of the invention, the track and track assembly are chosen to be used with “DualVee”® guide wheels (preferably in steel or stainless steel), manufactured by Bishop-Wisecarver Corporation. 
     In some embodiments of the present invention, methods of manufacturing track clamps having deformable teeth extrusions are disclosed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded view of a guided motion assembly requiring fasteners previously known in the art. 
         FIG. 2A  illustrates an end view of a fastener-less track assembly according to some embodiments of the present invention. 
         FIG. 2B  illustrates an isometric view of a fastener-less track assembly according to some embodiments of the present invention. 
         FIG. 2C  is an exploded view of a guided motion assembly without requiring fasteners according to some embodiments of the present invention. 
         FIG. 3A  illustrates an end view of a support base extrusion coupled with a pair of linear motion tracks via fastener-less track assemblies according to some embodiments of the present invention. 
         FIG. 3B  illustrates process steps for a method of manufacturing a guided motion system. 
         FIG. 4  illustrates a side view of an alternative support base extrusion coupled with a pair of linear motion tracks via fastener-less track assemblies according to some embodiments of the present invention. 
         FIG. 5  illustrates a side view of an alternative support base extrusion coupled with a pair of linear motion tracks via fastener-less track assemblies according to some embodiments of the present invention. 
         FIG. 6  illustrates a side view of an alternative support base extrusion coupled with a linear motion tracks via fastener-less track assemblies according to some embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Those of ordinary skill in the art will realize that the following detailed description of the present invention is illustrative only and is not intended to limit the claimed invention. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. It will be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer&#39;s specific goals. Reference will now be made in detail to implementations of the present invention as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed description to refer to the same or like parts. 
     Linear motion guides are used extensively in manufacturing processes and other applications. The support bases for linear motion guides are typically standard-sized extrusions. For example,  FIG. 1  illustrates an isometric schematic representation of a widely available aluminum extrusion support base  130  manufactured by the Parker Hannifin Corporation. Likewise, tracks and guide wheels for the linear motion guides are typically a standard manufacture and are commercially available. For example, the DualVee® guide wheel and Single Edge Track, both manufactured by Bishop-Wisecarver Corporation, are time-tested and ideal for a wide variety of applications. As discussed above, there is a need for an easy and reliable assembly for coupling a track to a support base. 
       FIG. 2A  illustrates a schematic end view of the fastener-less track assembly  200  for coupling a linear motion guide track, e.g.  297  ( FIG. 2C ),  320  ( FIG. 3A ),  420  ( FIG. 4 ), to a support base, e.g.  295  ( FIG. 2C ),  330  ( FIG. 3A ),  430  ( FIG. 4 ), according to the present preferred embodiments of the present invention. As shown, the track assembly  200  comprises two clamp arms  210 ,  220  that are connected to a base section  201  to form a well  230 . As shown, the two clamp arms  210 ,  220  extend vertically away from the base section  201  and terminate at a fixed distance from the base section  201 , thus defining the well  230 . 
     The well  230  is configured to accommodate a linear motion guide track, e.g.  297  ( FIG. 2C ),  320  ( FIG. 3A ),  420  ( FIG. 4 ). Two shoulders  211 ,  221  are disposed at the end, and on the outer sides of the clamp arms  210 ,  220 . As described, the track assembly  200  is configured to be inserted into a support base, e.g.  295  ( FIG. 2C ),  330  ( FIG. 3A ),  430  ( FIG. 4 ), such that the well  230  is disposed within the support base. Likewise, the support base, e.g.  295 ,  330 ,  430 , interacts with the shoulders  211 ,  221  such that the track assembly  200  rests upon the surface of the support base. Additionally, two sets of teeth protrusions  250  are disposed on the outer surfaces  240  of the clamp arms  210 ,  220 . In the present preferred embodiment of the present invention, the teeth protrusions  250  are configured such that they must be deformed to be inserted into a support base, e.g.  295 ,  330 ,  430 , thus providing a fastener-less coupling. 
     The teeth protrusions  250  are deformed and/or sheared by the press-fitting into a support base, e.g.  295 ,  330 ,  430 . Preferably, the deformation of the teeth protrusions  250  causes the clamp arms  210 ,  220  to be displaced toward each other (as indicated by the arrows). The displacement clamps a linear motion guide track, e.g.  297  ( FIG. 2C ),  320  ( FIG. 3A ),  420  ( FIG. 4 ), between the clamp arms  210 ,  220 , thereby securing the linear motion guide track therein. 
     In some embodiments of the present invention, the deformation of the teeth protrusions  250  effectuates galling between the track assembly  200  and a support base. In some embodiments of the present invention, the deformation of the teeth protrusions  250  effectuates a cold-pressure solid-state welding process. 
       FIG. 2B  illustrates an isometric schematic view of the assembly  200  according to the present preferred embodiment of the invention.  FIG. 2C  illustrates an exploded isometric view of a linear motion apparatus  299  comprising a guide wheel  298 , a linear motion guide track  297 , a track assembly  296 , and a support base extrusion  295 . 
     In some embodiments of the present invention, the guide wheel  298  is a DualVee® guide wheel manufactured by Bishop-Wisecarver Corporation. According to these embodiments, the guide wheel  298  is chosen from among “Original V Bearing Guide Wheels”, “Studded V Bearing Guide Wheels”, and “Integral V Bearing Guide Wheels”. 
     The “Original V Bearing Guide Wheels” consist of both an external and internal 90 degree “Vee” angle. The guide wheel is made with a double row angular contact bearing for excellent load capability and long life. V bearing guide wheels are preferably available in 52100 steel or 440C stainless steel from stock. Other options include seals and shields to meet specific application needs. Special DualVee® guide wheels are available for clean room, vacuum, and elevated temperature applications. Customer specific lubricants can also be used with the guide wheels. 
     The Studded guide wheels  298  combine the versatility and robustness of the DualVee® v bearing guide wheel  298  with convenience of a thru-hole mounting stud into a single piece. Concentric or eccentric stainless steel studs are riveted onto the wheels for a strong connection. 
     Integral V Bearing Guide Wheels offer a one piece construction. Sizes 2-4 steel wheels feature a one piece bushing or stud shaft with a machined inner bearing race. Sizes 0-1 steel and all polymer wheels utilize a riveted retaining technology to secure the wheel to the stud. Integral wheels add overmolded high performance polymer DualVee® wheels and MadeWell crown rollers to the DualVee® family to provide further component versatility. 
     In some embodiments of the present invention, the linear motion guide track  297  is a track manufactured by Bishop-Wisecarver Corp. and is especially designed for DualVee® guide wheels  298 . In some embodiments, the linear motion guide track  297  is a single edge linear motion guide track  297 , such as the “Vee” edge track, manufactured by Bishop-Wisecarver Corporation. For example, a single edge linear motion guide track  297  in 1045 carbon steel and 420 stainless steel from stock is available and would benefit from the present disclosure. At the “Vee” edge, a mounting shoulder is provided for quick reference during assembly. The single edge linear motion guide track  297  is able to be disposed with or without hardened “Vee surfaces”. Hardened linear motion guide track  297  comes in lengths of 20 feet, and can be easily butt-jointed for longer length applications. Non-hardened linear motion guide track  297  comes in lengths up to 22 feet, and also may be butt-jointed for longer lengths. Additionally, all single edge linear motion guide track  297  is able to be manufactured with or without drilled holes for mounting. “QuickTrak” series clamp extrusion is also available for fast and easy installation of size 3 DualVee® linear motion guide track  297 . 
       FIG. 3A  illustrates an end view of a guided motion system  300  comprising a support base  330  with a track assembly  325  and linear motion guide track  320 . As shown, the track assembly  325  is pressure fitted into the support base  330 . In some embodiments of the present invention, the track assembly  325  is configured such that it is easily coupled with the support base  330  using only basic tools. In the present preferred embodiment of the present invention, the track assembly  325  is configured such that a simple rubber mallet can easily force the track assembly  325  into the support base  330 . In some other embodiments, the track is able to be installed by using a cross-head arrangement of rollers  360  to uniformly apply force to insert the track clamp and track into standard structural extrusion support bases. However, it will be readily apparent to those having ordinary skill in the art that a wide variety of coupling mechanisms can be used. 
     The simple and secure coupling ability of the present invention provides distinct and extremely useful advantages of the approaches known in the art. For example, since linear motion tracks can be easily assembled without expensive and complicated tools, the cost savings of using the track assembly  325  is great. Additionally, the time to install a linear motion track is greatly reduced through the elimination of complicated assembly. By using a track assembly  325  that is compatible with standard extrusions, businesses do not need to invest in all new support bases and may provide consistency in their plant by using the same parts with the new assemblies. Furthermore, the track assemblies  325  of the present invention provide a more secure coupling than other fastener-less approaches. 
     First, as explained above, teeth protrusions  350  are disposed on the clamp arms  210 ,  220  of the track assemblies  325 . As a result of the pressure fitted coupling, the teeth protrusions  350  are deformed, thus ensuring a secure fit between the track assembly  325  and the support base  330 . Additionally, the shoulders  311 ,  321  provide additional support to the linear motion guide track  320 . For example, torque applied to the linear motion guide track  320  (indicated with arrows  358 ,  359 ) is resisted by the shoulders  311 ,  321 . 
     It will be readily apparent to those having ordinary skill in the art that the components disclosed in  FIG. 3A , and in other embodiments of the invention may take various sizes, shapes and appearance. In some embodiments, the clamp arms  210 ,  220  of the track assembly  325  are spaced between 3 mm and 12 mm apart. In some embodiments, the linear motion guide track  320 , the support base  330  and the track assembly  325  are between 3 m and 6 m long. In some embodiments, the track assembly  325  as recited is substantially comprised of steel. In some embodiments, the track assembly  325  as recited is substantially comprised of stainless steel. In some embodiments the track assembly  325  is formed by extrusion. In some embodiments the track assembly  325  is formed by metal injection molding. 
     In some embodiments of the present invention, the deformation of the teeth protrusions  350  effectuates galling between the track assembly  320  and a support base  330 . In some embodiments of the present invention, the deformation of the teeth protrusions  350  effectuates a cold-pressure solid-state welding process. 
       FIG. 3B  illustrates methods steps of manufacturing a guided motion system utilizing the novel track assembly of the present invention. The method starts by providing  396  a guided motion support base, providing  395  a linear motion guide track, and providing  394  a track assembly. Preferably, the linear motion guide track and track assembly are substantially axial. Likewise, the guided motion support base preferably has at least one conduit disposed therein for accepting the track assembly. In some embodiments of the invention, the track assembly has cross section that is substantially U-shaped and has a plurality of teeth protrusions disposed on the outside surface of the track assembly. 
     The method of manufacturing shown in  FIG. 3B  continues with coupling  397  the linear motion guide track with the track assembly. Next, the coupled track/track assembly is press-fitted  398  into the conduit of the support base. As explained above, a rubber mallet may easily tap the track/track assembly into the support base. According to some embodiments, the teeth protrusions on the track assembly are deformed when the track assembly is press-fitted in the support base, thus providing a secure coupling. Finally, the assembled guided motion apparatus is slidably coupled  399  with one or more guide wheels. 
     In some embodiments of the present invention, the method further comprises manufacturing the track, the support base and/or the track assembly. In some embodiments, the components are formed via an extrusion. In other embodiments, the components are formed by metal injection molding. 
       FIG. 3A  illustrates a support base  330  with two track assemblies  325  and two tracks  320 . However, it will be readily apparent to those having ordinary skill in the art, having the benefit of this disclosure, that a number of assembly configurations will benefit from the present invention.  FIGS. 4-6  illustrate schematic views of alternate embodiments of linear motion tracks utilizing novel track assemblies according to various embodiments of the present invention. 
       FIG. 4  illustrates an end schematic view of a linear motion apparatus  400  comprising a support base  430  disposed vertically between two guide wheels  440 ,  445 . The support base  430  is coupled to linear motion guide tracks  420  via track assemblies  425 . A plurality of teeth protrusions (not shown) are disposed on each of the track assemblies. As shown, the apparatus  400  is configured to move in and out of the page. 
     In some embodiments of the present invention, the deformation of the teeth protrusions (not shown) effectuates galling between the track assembly  425  and a support base extrusion  430 . In some embodiments of the present invention, the deformation of the teeth protrusions (not shown) effectuates a cold-pressure solid-state welding process. 
       FIG. 5  illustrates an end schematic view of a linear motion apparatus  500  comprising a support base  530  disposed vertically between two guide wheels  540 ,  545 . The support base  530  is coupled to linear motion guide tracks  520  via track assemblies  525 . A plurality of teeth protrusions (not labeled) are disposed on each of the track assemblies  525 . As shown, the linear motion apparatus  500  is configured to move in and out of the page. 
     In some embodiments of the present invention, the deformation of the teeth protrusions (not shown) effectuates galling between the track assembly  525  and a support base extrusion  530 . In some embodiments of the present invention, the deformation of the teeth protrusions (not labeled) effectuates a cold-pressure solid-state welding process. 
       FIG. 6  illustrates an end schematic view of a linear motion apparatus  600  comprising a support base  630  disposed vertically between two guide wheels  640 ,  645 . The support base  630  is coupled to a linear motion guide track  620  via track assembly  625 . A plurality of teeth protrusions  627 ,  628  are disposed on the track assembly  625 . As shown, the linear motion apparatus  600  is configured to move in and out of the page. 
     In some embodiments of the present invention, the deformation of the teeth protrusions  627 ,  628  effectuates galling between the track assembly  625  and a support base  630 . In some embodiments of the present invention, the deformation of the teeth protrusions  627 ,  628  effectuates a cold-pressure solid-state welding process. 
     The track assembly  625  is substantially axial (in and out of page) and includes a substantially axial plug section  626  with a plurality of teeth protrusions  627 ,  628  disposed on the outer sides of the plug section  626 . Additionally, the plug section  626  includes a substantially axial cap section  629  that is coupled to the plug section  626 , wherein the cap section  629  is at least partially wider than the plug section  626 , forming shoulders  631 ,  632  which rest upon the surface of the support base  630  when the track assembly  625  is coupled with the support base  630 . Furthermore, a well  635  is disposed in the cap section  629 , and is configured to hold the linear motion guide track  620  therein. According to some embodiments of the present invention, and as shown in  FIG. 6 , the orientation of the well  635  within the cap section  629  is substantially orthogonal to the orientation of the plug section  626 . In the preferred embodiment of the present invention, the cap section  629  and the plug section  626  are integral. 
     The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It will be apparent to those skilled in the art that modifications can be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention. Specifically, it will be apparent to one of ordinary skill in the art that the device and method of the present invention could be implemented in several different ways and have several different appearances.