Flex-arm devices and methods

Disclosed is a flex-arm device including a base, at least one support block attached to the base, the support block including a shaft aperture, a shaft engaged with the shaft aperture of the support block, and a flex-arm mount attached to the shaft. When the device is in an unlocked orientation, the shaft is capable of rotation within the shaft aperture such that the flex-arm mount may be angularly displaced about multiple positions, and when the device is in a locked orientation, the shaft is restricted from rotation within the shaft aperture.

TECHNICAL FIELD

The invention relates to devices and methods utilized in varying a contact angle between a flex-arm mounted grinding wheel and a surface to be ground.

BACKGROUND

Accurately-ground angled surfaces are often necessary in manufacturing processes. The accuracy of these ground surfaces depends heavily upon the contact angle of an employed precisely-shaped grinding wheel. In many applications, these grinding wheels are mounted on flex-arms only capable of movement in the directional axes of forward and backward, side to side and up and down. In such applications, the flex-arm mounted grinding wheel is therefore only able to accurately grind a surface parallel or perpendicular to the surface on which the flex-arm is mounted. Accordingly, the grinding of angled surfaces in an accurate manner with a flex-arm mounted grinding wheel is difficult due to the limited dynamism provided by the flex-arm.

SUMMARY

One embodiment of a flex-arm device includes a base, at least one support block attached to the base, the support block including a shaft aperture, a shaft engaged with the shaft aperture of the support block, and a flex-arm mount attached to the shaft. When the device is in an unlocked orientation, the shaft is capable of rotation within the shaft aperture such that the flex-arm mount may be angularly displaced about multiple positions, and when the device is in a locked orientation, the shaft is restricted from rotation within the shaft aperture.

Another embodiment of a flex-arm device includes a base, a pair of support blocks attached to the base, each support block comprising a shaft aperture and a set member aperture, a shaft engaged with the shaft apertures, two threaded set members that cooperate with a threaded portion of the set member apertures, and a flex-arm mount attached to the shaft. Rotation of at least one of the set members controls a circumference of at least one of the shaft apertures, wherein when the circumference of at least one of the shaft apertures is the same as a circumference of the shaft, the device is in a locked orientation, and the shaft is restricted from rotation within the shaft aperture, and wherein when the circumferences of the shaft apertures are larger than the circumference of the shaft, the device is in an unlocked orientation, and the shaft is capable of rotation within the shaft aperture such that the flex-arm mount may be angularly displaced about multiple positions.

One embodiment of a method of angling a flex-arm mounted grinding wheel includes providing a flex-arm device comprising a base, at least one support block attached to the base, the support block including a shaft aperture, a shaft engaged with the shaft aperture of the support block, and a flex-arm mount attached to the shaft; engaging a flex-arm with the flex-arm mount, the flex-arm having a grinding wheel mounted thereon; and angling the grinding wheel through rotation of the shaft within the shaft aperture, wherein the flex-arm mount may be angularly displaced about multiple positions through rotation of the shaft, such that the flex-arm engaged with the flex-arm mount may be tilted to multiple positions through the angular displacement of the flex-arm mount, such that the grinding wheel may be tilted through the tilting of the flex-arm.

These and additional features can be more fully understood in view of the following detailed description, in conjunction with the drawings.

DETAILED DESCRIPTION

As will be discussed in relation to the figures, embodiments of a flex-arm device100may include a base110, at least one support block120, a shaft130and a flex-arm mount140. It should be understood, however, that other embodiments of device100may include additional structure, such as, for example, a measuring block150.

Referring toFIGS. 1-6, base110may be utilized in the stabilization or attachment of device100to any surface. Base110may take any shape and/or size and may stabilize or attach device100to a surface by any method known in the art. In the illustrated embodiment, base110includes a flat, rectangular magnetic chuck111. Through employment of magnetic chuck111, base110may be utilized to stabilize and/or magnetically attach device100to a metal surface plate, metal die or any other magnetically attractive metal surface. Magnetic chuck111of the illustrated embodiment includes a bottom plate112, a middle portion113, a top plate114and a switch115. As depicted inFIG. 2, bottom plate112, middle portion113and top plate114may all be flat in shape, and therefore, the overall magnetic chuck may also be flat in shape. As depicted inFIGS. 4-6, this flat shape enables top plate114to be parallel with a flat surface170to which magnetic chuck111may be attached.

Switch115may toggle between a first position (as depicted inFIGS. 1-3) and a second position (rotated 180 degrees to the right). When switch115is in a first position, magnetic chuck111may be in a demagnetized arrangement, and when switch115is in a second position, magnetic chuck111may be in a magnetized arrangement. When magnetic chuck111is in a demagnetized arrangement, a user may be able to change the position of device100on a surface. When magnetic chuck111is in a magnetized arrangement on a metal surface, device100may be magnetically secured into position. However, embodiments of device100need not include a base that includes magnetic chuck111.

Other embodiments of device100may include a base that primarily makes use of the weight of the base and the rest of the device (as well as the weight of an engaged flex-arm) for stabilization on a surface. Again, the base of such embodiments may be of any size and/or shape for a particular application. Embodiments of device100may also include a base that employs one or more fasteners to attach and stabilize device100on a surface. Additional embodiments of device100may include a base for permanent attachment of device100on a surface through welding, soldering, adhering and/or bonding.

As shown inFIGS. 1-6, embodiments of device100may include base110that incorporates a mounting plate116and handles117. In such embodiments, mounting plate116may take any shape and/or size and may attach to magnetic chuck111through any method known in the art. Non-limiting examples of attachment include utilization of fasteners, welding, soldering, adhering, boding and the like. The illustrated embodiment includes a flat and rectangular-shaped mounting plate to mirror top plate114of magnetic chuck111. The flat shape of mounting plate116enables the mounting plate to be parallel with top plate114(as shown inFIG. 2), which may be parallel with a flat surface to which magnetic chuck111is attached (as shown inFIGS. 4-6). Mounting plate116may be utilized as a mount for handles117, support blocks120, and other elements of device100. However, base110need not include mounting plate116, as elements of device100may also mount directly on magnetic chuck111. Handles117may be of any shape, size and/or number and may be useful in the transport and positioning of device100. The illustrated embodiment of device100includes two handles117, with each handle comprising a cylinder118welded to two extensions119that are mounted to mounting plate116through the utilization of fasteners. However, welding and/or fasteners need not be employed, as any method of attachment know in the art may be utilized. Additionally, base110need not include handles117.

Still referring toFIGS. 1-6, at least one support block120may be utilized in supporting shaft130of device100. Any number of support blocks120may be included in embodiments of device100, and support block(s)120may take any shape and/or size. Support block120may attach to mounting plate116or magnetic chuck111through any method known in the art. Non-limiting examples include utilization of fasteners, welding, soldering, adhering, boding and the like. The illustrated embodiment of device100includes two support blocks120that incorporate feet121that attach to mounting plate116through the utilization of fasteners. However, feet121need not be included on support block120and any method of attaching the support block to either mounting plate116or magnetic chuck111may be utilized. Additionally, further embodiments of device100may include support block(s)120and mounting plate116formed together in a one-piece construction.

As shown inFIG. 3, support block120may include an opening that comprises a shaft aperture122and a channel123. Shaft aperture122is round-shaped and sized slightly larger than shaft130. Therefore, shaft130may fit within shaft aperture122and still have freedom to rotate within shaft aperture122. Support block120may also include one or more additional apertures for cooperation with a set member and/or a support member. As shown inFIGS. 1 and 2, the illustrated embodiment of device100includes support blocks120with set member apertures124and support member apertures125. Set member aperture124may travel from an opening on the front126of support block120, completely through the support block (therefore crossing channel123), to the rear127of the support block. Set member aperture124may or may not include a second opening on rear127of support block120. At least a portion of the section of set member aperture124from rear127of support block120to channel123may be threaded for further cooperation with a set member. Additionally, set member aperture124may include a countersink portion at front126of support block120for cooperation with a head of a set member. Support member aperture125may travel from an opening on the front126of support block120to an opening on the circumference of shaft aperture122. At least a portion of support member aperture125may be threaded for further cooperation with a support member.

Embodiments of device100may include a set member128that comprises a threaded bolt to cooperate with the threaded portion of set member aperture124, and may be rotated through utilization of an Allen Wrench (a.k.a., hex key wrench). As shown in the illustrated embodiment, set member128may fit within set member aperture124, wherein the head of the set member may at least partially fit within the countersink portion of the set member aperture. Rotation of set member128in one direction will advance the set member along the threaded portion of set member aperture124. When the head of set member128is unable to advance further into the countersink portion of set member aperture124, continued rotation of set member128may cause rear127of support block120and front126of support block120to move closer together. Accordingly, the width of channel123and the circumference of shaft aperture122may decrease. When shaft130is engaged within shaft aperture122, the circumference reduction of shaft aperture122may restrict and/or stop the ability of the shaft to rotate within the shaft aperture, thus locking the shaft in position. When shaft130is restricted from rotation within shaft aperture122, device100is in a locked orientation. Rotation of set member128in the opposite direction may retract set member128through set member aperture124. Accordingly, when shaft130is in a locked orientation, rotation of set member128in the opposite direction may release the device from the locked orientation and allow the shaft to rotate. When shaft130is capable of rotation within shaft aperture122, device100is in an unlocked orientation. However, embodiments of device100need not include set member128, as any method or structure now or hereafter known in the art can be utilized to restrict and/or stop the rotation of shaft130with shaft aperture122.

Embodiments of device100may include a support member129. The illustrated embodiment includes support member129that comprises a nylon-tipped threaded bolt to cooperate with threaded portion of support member aperture125. As shown in the illustrated embodiment, at least a portion of support member129may fit within support member aperture125, and rotation of the support member in one direction will advance the support member along the threaded portion of support member aperture125. When shaft130is engaged within shaft aperture122, support member129may advance along support member aperture125until the nylon tip of the support member contacts shaft130. The contact between the nylon tip of support member129and shaft130may maintain the shaft from disengaging with shaft aperture122, but such contract is not meant to substantially restrict rotation of the shaft within the shaft aperture. Rotation of support member129in the opposite direction may retract support member129through support member aperture125. Accordingly, when shaft130is not contacted by support member129, and the shaft is also not in a locked orientation through utilization of set member128, the shaft may be able to be removed from shaft aperture122. However, embodiments of device100need not include support member129.

Referring toFIGS. 1-6, shaft130may be utilized in the rotation of flex-arm mount140. As shown in the illustrated embodiment, and as described above, shaft130may be precisely round in shape to engage with shaft aperture122of support block120. Shaft130may further include flat sections notched into the shaft to assist in precise attachment of a measuring block and a receiving member plate to the shaft. Shaft130may be hollow or solid and of any circumference and/or length for a particular embodiment of device100. As depicted inFIG. 2, shaft may be in a substantially flush engagement with an opening of a shaft aperture of a first support block and extend outward from an opening of a shaft aperture of a second support block. The extension of shaft130may extend outward from a shaft aperture for the attachment of a measuring block or other element of device100. However, in other embodiments, shaft130may be in a flush engagement with the openings of the shaft apertures of more than one support block, or the shaft may extend outward from the openings of the shaft apertures of more than one support block. Shaft130may further include apertures (not shown) for the utilization of fasteners to attach flex-arm mount140and measuring block150to the shaft.

Referring toFIGS. 1-6, flex-arm mount140may be utilized in the engagement of flex-arm160to device100. Flex-arm mount140may take any shape and/or size and may stabilize or attach flex-arm160to device100by any method known in the art. In the illustrated embodiment, flex-arm mount140includes a two-diameter flex-arm receiving member141and a receiving member plate142. The illustrated embodiment includes receiving member plate142that is flat and square-shaped. However, receiving member plate may be of any shape and/or size. Receiving member141may attach to receiving member plate142through any method known in the art. Non-limiting examples include utilization of fasteners, welding, soldering, adhering, boding and the like. The illustrated embodiment of device100includes receiving member141that attaches to receiving member plate142through the utilization of fasteners. Receiving member plate142may attach to shaft130through any method known in the art. Non-limiting examples include utilization of fasteners, welding, soldering, adhering, boding and the like. The illustrated embodiment of device100includes receiving member plate142that attaches to shaft130through the utilization of fasteners (not shown).

As depicted inFIG. 1, receiving member141may be formed of a one-piece construction with two diameters. The lower/larger diameter is utilized in the attachment of receiving member141to receiving member plate142. The upper/smaller diameter includes a recess143utilized to engage at least a portion of extension member161of flex-arm160. As shown inFIGS. 1 and 2, the top surface144of receiving member141and the bottom surface (not shown) of recess143may be flat and parallel to the bottom surface145of the receiving member. Accordingly, top surface144of receiving member141and bottom surface of recess143may be parallel to the attached flat receiving member plate142.

The engagement of flex-arm extension member161and receiving member141of device100may be a “slip-fit engagement.” A “slip-fit engagement” is herein defined as at least a portion of an extension member snugly fitting within a recess without the employment of fasteners. A slip fit engagement utilizing a round-shaped extension member and round-shaped recess, as in the illustrated embodiment, may therefore allow for rotation of the extension member within the recess. As depicted inFIGS. 4-6, flex-arm extension member161may be supported within recess143, while also being free to rotate within the recess. Accordingly, flex-arm160may be supported on device100, but still free to rotate from side to side. However, embodiments of device100need not include flex-arm mount140that employs a slip fit engagement with flex-arm160. Any method of engagement may be employed, including methods that utilize fasteners.

Referring toFIGS. 1-6, measuring block150may be utilized in measuring the angle of attached flex-arm160(and therefore the angle of a flex-arm mounted grinding wheel162) in relation to the surface on which device100is attached. Measuring block150may take any shape and/or size and may be utilized to measure angles by any method known in the art. Measuring block150may be solid, or, as in the illustrated embodiment, may include cut-away portions to reduce the weight of device100. Measuring block150may include a flat top surface151for utilization in the measuring of the angle of flex-arm mounted grinding wheel162in relation to the surface on which device100is attached. Measuring block150may attach to shaft130through any method known in the art. Non-limiting examples include utilization of fasteners, welding, soldering, adhering, boding and the like. The illustrated embodiment of device100includes measuring block150that attaches to shaft130through the utilization of fasteners (not shown). As illustrated inFIGS. 2 and 3, measuring block150may be attached to shaft130in an orientation where top surface151is parallel to receiving member plate142of flex-arm mount140. Top surface151is therefore also parallel with top surface144of receiving member140and the bottom surface of recess143. Accordingly, when flex-arm160is engaged with flex-arm mount140, top surface151may also be parallel with the bottom surface of a precisely shaped grinding wheel162that is mounted on the flex-arm, as shown inFIGS. 4-6. The parallel nature of these surfaces allows a measurement of the angle of inclination of top surface151of measuring block150to provide an accurate measurement of the angle of inclination of flex-arm mounted grinding wheel162. Any device, gauge or method of measuring an angle may be employed with measuring block150for the measurement of such angles.

The structure of device100, including the structure of the individual components (for example, base110, support block120, shaft130, flex-arm mount140and measuring block150), may be composed of any suitable material, or combination of materials, now or hereafter known in the art. Non-limiting examples include steel, iron, aluminum, titanium and any other various metal or alloy. The illustrated embodiments are constructed of steel. However, it is not necessary for all individual components of the embodiments of device100to be composed of the same material. Certain embodiments of device100may include components made from different materials, such as embodiments made of both steel and aluminum.

A flex-arm is generally capable of movement along multiple directional axes. Herein, the term “flex-arm” means any mechanical arm or boom that is capable of dynamism along at least two directional axes. As depicted inFIGS. 4-6, and for purposes of non-limiting illustration only, flex-arm160is capable of moving in the directional axes of forward and backward, side to side and up and down. Accordingly, grinding wheel162mounted on flex-arm160is also capable of dynamism in the directional axes of forward and backward, side to side and up and down. However, in certain applications, grinding wheel162may be required to contact a surface to be ground at a precise angle. Accordingly, use of the illustrated embodiment of device100allows a user to tilt the entire flex-arm160, and thus grinding wheel162as well, forward or backward to the precise angle required by a particular application. Moreover, while flex arm160and grinding wheel162are angularly displaced (i.e., tilted) in any one of multiple positions, the grinding wheel is still able to move along at least two directional axes through utilization of the dynamism of the flex-arm. Accordingly, through utilization of device100, flex-arm mounted grinding wheel162is capable of at least two types of displacement: a first type of displacement that allows the grinding wheel to move along at least two directional axes through utilization of a dynamism provided by flex-arm160, and a second type of displacement that allows the grinding wheel to tilt through the tilting of the flex-arm through the angular displacement of flex-arm mount140of the device.

Referring toFIGS. 1-6, when utilizing the illustrated embodiment of device100, a user may position the device on a surface170. In applications where the surface comprises a magnetically-attractive metal, the user may toggle switch115to place magnetic chuck111in a magnetized arrangement, and therefore magnetically secure device100to surface170. Employing a slip-fit arrangement, a user may then place an extension member161of a flex-arm160into recess143of flex-arm mount140. Referring specifically toFIGS. 1 and 2, if device100(now engaged with a flex-arm) is in a locked orientation, a user may rotate set member(s)128to retract the set member(s) from set member apertures124. The retraction of set member(s)128will convert device100to an unlocked orientation. While in the unlocked orientation, shaft130may rotate within shaft aperture122, which will allow the attached flex-arm mount140and measuring block150of device100to be angularly displaced into a multitude of positions. This angular displacement of flex-arm mount140will allow the entire engaged flex-arm160(and therefore flex-arm mounted grinding wheel162) to tilt forward or backward into a multitude of positions. In some embodiments of device100, flex-arm mount140and measuring block150are capable of a range of angular displacement of 185 degrees. Accordingly, engaged flex-arm160may be capable of tilting forward slightly more than 90 degrees from an upright arrangement (depicted inFIG. 4), as well as capable of tilting backward slightly more than 90 degrees from an upright arrangement. When flex-arm mount140is angularly displaced into a desired position, and therefore, when flex-arm mounted grinding wheel162is tilted to a desired position, a user may rotate set member(s)128to advance them in set member aperture(s)124. As described above, this advancement of set member(s)128will decrease the width of channel(s)123and the circumference of shaft aperture(s)122, restricting shaft130from rotation and placing device100into a locked orientation.

Flex-arm mount140(and therefore flex-arm160and mounted grinding wheel162) can be set and reset into a multitude of positions.FIG. 4shows device200with an engaged flex-arm160in an upright arrangement (as doesFIGS. 1 and 2, without an engaged flex-arm), wherein the sides of grinding wheel162are perpendicular to mounting surface170and the bottom of grinding wheel162is parallel to mounting surface170. The sides of grinding wheel162are also perpendicular to receiving member plate142and top surface151of measuring block150, and the bottom of grinding wheel162is parallel to receiving member plate142and top surface151of measuring block150. In this arrangement, grinding wheel162mounted to flex-arm160may still be able to move in the directions of forward and backward, side to side and up and down, but the sides of grinding wheel162will remain perpendicular to mounting surface170, receiving member plate142and top surface151of measuring block150, and the bottom of grinding wheel162will remain parallel to mounting surface170and receiving member plate142and top surface151of measuring block150.

FIG. 5depicts device300with an engaged flex-arm in a backward-tilted arrangement (as doesFIG. 3, without an engaged flex-arm), andFIG. 6depicts device400with an engaged flex-arm in a forward-tilted arrangement. Like in the upright arrangement ofFIG. 4, the sides of grinding wheel162remain perpendicular to receiving member plate142and top surface151of measuring block150, and the bottom of grinding wheel162is parallel to receiving member plate142and top surface151of measuring block150. However, the sides and bottom of grinding wheel162are angled with respect to mounting surface170. Therefore, measuring the angle of top surface151of measuring block150(with respect to mounting surface170) will indicate the angle (again, with respect to mounting surface170) of the sides and bottom of grinding wheel162. In these arrangements, grinding wheel162mounted to flex-arm160may still be able to move in the directions of forward and backward, side to side and up and down, but the sides of grinding wheel162will remain perpendicular to receiving member plate142and top surface151of measuring block150, and the bottom of grinding wheel162will remain parallel to receiving member plate142and top surface151of measuring block150. For illustration,FIG. 5depicts flex-arm mounted grinding wheel162that is positioned further away from extension member161when compared to the positions of the flex-arm mounted grinding wheels162ofFIGS. 4 and 6(i.e., through movement afforded by the dynamism of flex-arm160, grinding wheel162was moved forward along a directional axis farther inFIG. 5than inFIGS. 4 and 6). As shown inFIG. 5, even though moved forward through the dynamism of flex-arm160, the bottom of grinding wheel162remains parallel to top surface151of measuring block150. Accordingly, a measured angled surfaced may be accurately ground through utilization of device100.

While particular embodiments and aspects of the present invention have been illustrated and described herein, various other changes and modifications can be made without departing from the spirit and scope of the invention. Moreover, although various inventive aspects have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of this invention.