Systems and methods for modular instrument design and fabrication

Abstract

Modular component mounting systems and methods employ a plurality of members adapted to be interlocked with one another and anchored to an instrument housing. Each of the members comprises a central elongated body, cross-holes extending transversely through the body, beads extending along corners of the body to a position spaced apart from an end of the body defining a key at the end of the body, a channel defined by a surface of the body and a pair of the beads to receive and register with a key of another member, and a fastener receptive orifice defined in the end of the body. A fastener extends though one of the cross-holes of a first member to be received by an end orifice of a second member, interlocking the members and preventing torsional movement by the members relative to one another.

1 . A member comprising: 
 a central elongated body portion;    at least one cross-hole extending transversely through said central body portion;    bead portions extending along at least a pair of corners of said body portion, said bead portions extending to a position along said body portion, spaced apart from an end of said body portion, to provide a key portion of said body portion;    a channel portion defined by a surface of said body portion and a pair of said bead portions, said channel portion adapted to receive an end of another member and register with a key portion of said another member; and    a fastener receptive orifice defined in said end of said body portion;    
   
   
       2 . The member of  claim 1 , wherein said at least one cross-hole comprises a plurality of cross-holes for indexing with component mounting grids.  
   
   
       3 . The member of  claim 1 , wherein at least one of said at least one cross-hole is elongated along a length of said member, defining a slot.  
   
   
       4 . The member of  claim 1 , wherein said body portion has a generally square cross section.  
   
   
       5 . The member of  claim 1 , wherein said orifice is threaded to threadably receive a fastener.  
   
   
       6 . The member of  claim 1 , wherein said orifice is defined by a central cannula extending through a length of said body portion.  
   
   
       7 . The member of  claim 1 , wherein said member is extruded.  
   
   
       8 . The member of  claim 1 , wherein said member is adapted to be used as a heat sink for at least one of said components.  
   
   
       9 . A modular system comprising: 
 a plurality of members adapted to be interlocked with one another and anchored to an instrument housing structure, each of said members comprising:    a central elongated body portion;    at least one cross-hole extending transversely through said central body portion;    bead portions extending along at least a pair of corners of said body portion, said bead portions extending to a position spaced apart from an end of said body portion to define a key portion at said end of said body portion;    a channel portion defined by a surface of said body portion and a pair of said bead portions, said channel portion receiving and registering with a key portion of another member; and    a fastener receptive orifice defined in said end of said body portion;    a fastener extending though one of said cross-holes of a first of said members to be received by an end orifice of a second of said members, interlocking said first and second members and preventing torsional movement by said members relative to one another.    
   
   
       10 . The system of  claim 9 , wherein an orientation of said second member are selected based on a desired orientation of said cross-holes of said second member.  
   
   
       11 . The system of  claim 10 , wherein said desired orientation of said cross-holes of said second member are based on mounting provisions provided by one or more of said components.  
   
   
       12 . The system of  claim 9 , wherein said at least one cross-hole comprises a plurality of cross-holes indexing with a component mounting grid.  
   
   
       13 . The system of  claim 9 , wherein at least one of said cross-holes is elongated along a length of said member, defining a slot.  
   
   
       14 . The system of  claim 9 , wherein at least one of said members is adapted to be used as a heat sink for at least one of said components.  
   
   
       15 . The system of  claim 9 , wherein channels of a pair of spaced apart members are adapted to be used as a card guide for a circuit board of said instrument, said channels of said spaced apart members each receiving and retaining an edge of said circuit board.  
   
   
       16 . The system of  claim 9 , further comprising a hinge assembly, said hinge assembly comprising: 
 an anchored member;    a first fastener extending through a cross-hole of said anchor member;    a generally tubular element adapted to receive said fastener in a first end;    a frame member; and    a second fastener extending through a cross-hole of said frame member, said second fastener received by an opposite end of said generally tubular element;    wherein said frame member and any instrument component attached thereto pivots at said generally tubular member, at least partially about said anchor member.    
   
   
       17 . The system of  claim 9 , further comprising a truss, said truss comprising 
 at least a pair of generally parallel, spaced apart, cord members arranged with channel portions of said cord members facing each other;    at least one strut-tie members extending between said cord members, key portions of said strut-tie members received by said channel portions of said cord members; and    fasteners extending though cross-holes of each of said cords and received by end orifices of said strut-tie members, torsionally interlocking said cord members and said strut tie members in a truss configuration.    
   
   
       18 . A method comprising: 
 keying an end of a first beam member with a channel defined by a second beam member;    receiving a fastener through a hole defined by said second beam member into an orifice defined in an end of said first beam member;    securing said fastener to torsionally interlock said first and second beam members; and    mounting instrument components to the interlocked beam members to provide an instrument.    
   
   
       19 . The method of  claim 18 , further comprising indexing component mounting grids with said beam members for said mounting.  
   
   
       20 . The method of  claim 18 , further comprising: 
 selecting an orientation of said first beam member based on a desired orientation of said cross-holes of said first beam member for mounting one or more of said components.    
   
   
       21 . The method of  claim 18 , further comprising: 
 anchoring said second beam member to an instrument housing structure.    
   
   
       22 . The method of  claim 18 , further comprising: 
 threading said fastener into said orifice.    
   
   
       23 . The method of  claim 18 , further comprising: 
 adjusting a position of said components along said beam members.    
   
   
       24 . A method comprising: 
 anchoring modular beam members to an instrument housing structure;    interlocking beam members disposed in said instrument housing structure with the anchored beam members;    mounting instrument components to the interlocked beam members; and    interconnecting said instrument components to provide an instrument.    
   
   
       25 . The method of  claim 24 , further comprising indexing: 
 component mounting grids with said beam members for said mounting.    
   
   
       26 . The method of  claim 24 , further comprising: 
 interlocking other beam members disposed in said instrument housing structure with the beam members interlocked with said anchored beam members.    
   
   
       27 . The method of  claim 24 , further comprising: 
 adjusting a position of said components along said beam members.