Apparatus and method for positioning headlamps on a front cross member

Abstract

The application discloses a device and method for positioning headlamps on a front bumper cross beam, comprising a headlamp support, a front bumper cross beam and a positioning tool. The headlamp support is two thin plates with a 90-degree angle, and a plurality of through holes with a diameter deviation of ±0.5mm are arranged on the first thin plate. A plurality of internal thread holes are arranged on the front bumper cross beam, and the diameter of the internal thread holes is smaller than that of the through holes on the thin plate. The positioning tool is a rectangular base plate, and four positioning columns are arranged on the base plate to position the relative position of the headlamp support and the front bumper cross beam. A plurality of groups of adjustable support structures in XYZ directions are designed on the front bumper cross beam, and a plurality of combined toolings are simultaneously manufactured, including a positioning tooling for the front bumper cross beam support on the front bumper cross beam and a positioning tooling for the front bumper cross beam assembly on the vehicle body. Through the above structure and tooling scheme design, the comprehensive deviation of the front headlamp II mounting point on the front bumper cross beam relative to the front end of the whole vehicle can be finally controlled within ±1.0mm from ±3mm, and finally the appearance DTS reaches 2.0±1.2mm, which is higher than the industry evaluation level of 2.0±1.5mm.

Description

Technical Field

[0001] This invention belongs to the field of automotive dimensional engineering technology, specifically a device and method for positioning headlights on the front bumper crossbeam. Background Technology

[0002] With the development of automotive electrical systems, the trend towards dual main headlight designs is becoming increasingly apparent, including both the Headlight I assembly and the Headlight II assembly. The Dual Main Headlights and other environmental components such as the front bumper require simultaneous assurance of DTS (Dimensional Tolerance Standard), generally within the industry standard of 2.0 ± 1.5 mm. The positioning method of the Headlight I assembly is similar to that of traditional vehicles, the technology is relatively mature, and the appearance is guaranteed. However, due to its unique location, the Headlight II assembly cannot be integrated with structures such as the fenders and must be directly mounted to the front bumper crossbeam. This results in poor mismatch between the clearance between the Headlight II and the front bumper, leading to a high DTS deviation rate, with a maximum deviation of approximately ± 3.0 mm. Dimensional analysis reveals that the main reason for the deviation in the Headlight II is the large precision deviation of the front bumper crossbeam, with a single-piece tolerance level of ± 1.5 mm and a mounting point deviation of ± 1.5 mm, failing to meet the precise positioning requirements of the Headlight II. Summary of the Invention

[0003] To address the above problems, this invention provides a device and method for positioning headlights on the front bumper crossbeam. The deviation of a single front bumper crossbeam component is ±1.5mm horizontally, the installation point deviation is ±1.5mm, and the maximum deviation is ±3mm; ultimately leading to a deviation in the clearance between the headlight II and the front bumper circumference. This invention designs multiple sets of XYZ-axis adjustable bracket structures on the front bumper crossbeam and manufactures various combined tooling, including positioning tooling for the front bumper crossbeam brackets on the front bumper crossbeam and positioning tooling for the front bumper crossbeam assembly on the vehicle body. Through the above structural and tooling design, the overall deviation of the headlight II installation point on the front bumper crossbeam relative to the front end of the vehicle can be controlled from ±3mm to within ±1.0mm, ultimately ensuring a visual DTS (Distinctness Tolerance) of 2.0±1.2mm, higher than the industry standard of 2.0±1.5mm.

[0004] The technical solution of the present invention is as follows: a device for positioning headlights on a front bumper crossbeam, comprising: a headlight bracket, a front bumper crossbeam, and a positioning fixture;

[0005] The headlight bracket consists of two thin plates integrally formed at a 90-degree angle. The first thin plate has multiple through holes, and the second thin plate has multiple headlight bracket positioning holes, snap-fit ​​structure, and hollow structure.

[0006] The front bumper crossbeam is the first crossbeam behind the front bumper of a car, and it has multiple internal threaded holes and multiple front bumper crossbeam positioning holes.

[0007] The positioning device includes a base plate with multiple positioning rods and multiple positioning blocks on the positioning rods. The positioning blocks are connected to the positioning rods through adjusting shims and are equipped with positioning pins. The positioning pins can match the positioning holes of the headlight bracket and the front bumper beam to fix the spatial position of the front bumper beam and the headlight bracket.

[0008] Furthermore, the positioning block, adjusting shim, and positioning rod are bolted together.

[0009] Furthermore, the diameter of the internal threaded hole on the front bumper beam is smaller than the diameter of the through hole on the first thin plate.

[0010] Furthermore, there are four or more positioning rods, each positioning rod has three or more positioning blocks, each positioning block is equipped with an adjusting shim, and at least one positioning block is equipped with a positioning pin.

[0011] Furthermore, the substrate is a cuboid with a rectangular top surface. The adjustment shims are divided into X-axis adjustment shims, Y-axis adjustment shims, and Z-axis adjustment shims. The X-axis adjustment shims are perpendicular to the substrate and face the short side of the top surface of the substrate. The Y-axis adjustment shims are perpendicular to the substrate and also perpendicular to the X-axis adjustment shims. The Z-axis adjustment shims are parallel to the substrate.

[0012] Furthermore, the thickness of the adjusting shim is 0.1mm-5mm.

[0013] A method for positioning headlights on a front bumper crossbeam includes the following steps:

[0014] Place the front bumper beam on the positioning fixture and fix its position by matching the positioning pin with the positioning hole of the front bumper beam.

[0015] Place the headlight bracket on the front bumper crossbeam and fix the spatial position of the headlight bracket and the front bumper crossbeam by matching the positioning pin with the positioning hole of the headlight bracket.

[0016] By adjusting the thickness of the shims, the headlight bracket and the front bumper crossbeam are positioned to meet the standard.

[0017] Use bolts that match the internal threaded holes of the front bumper beam to pass through the through holes in the first thin plate to fix the headlight bracket to the front bumper beam. Measure the distance between the headlight bracket and the front bumper beam, and make fine adjustments through the through holes in the first thin plate until the distance meets the requirements.

[0018] The beneficial effects of this invention are as follows:

[0019] To meet the precision requirements of the entire vehicle, the front bumper crossbeam structure was optimized by separating an XY-axis adjustable bracket for positioning the combination lamp II. A reasonable assembly strategy was developed, with the headlight bracket and front bumper separately assembled using tooling to ensure a relative positional deviation of ±0.3mm between the headlight bracket and the front bumper crossbeam in the XY direction. The headlight bracket and front bumper crossbeam were then positioned. Finally, the entire front bumper crossbeam was connected to the front-end reference of the vehicle body using tooling, ensuring a relative deviation of ±0.5mm between the front bumper crossbeam and the vehicle body reference in the YZ direction. Through this solution, by disassembling the bracket on the front bumper crossbeam and connecting it with two sets of tooling, the positional deviation of the headlight bracket relative to the vehicle body can be effectively controlled within ±1.0mm. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of a car headlight.

[0021] Figure 2 This is a schematic diagram of the front bumper beam and headlight bracket of the present invention.

[0022] Figure 3 This is a schematic diagram of the headlight bracket of the present invention installed on the front bumper crossbeam.

[0023] Figure 4 This is a schematic diagram I of the headlight bracket of the present invention.

[0024] Figure 5 This is a schematic diagram (II) of the headlight bracket of the present invention.

[0025] Figure 6 This is a schematic diagram of the positioning device of the present invention (I).

[0026] Figure 7 This is a schematic diagram (II) of the positioning device of the present invention.

[0027] Figure 8 This is a schematic diagram (I) of the positioning device of the present invention.

[0028] Figure 9 This is a schematic diagram (II) of the positioning device of the present invention.

[0029] Figure 10 This is a schematic diagram of the positioning device for positioning the headlight bracket of the present invention.

[0030] In the picture:

[0031] 1-Headlight I; 2-Gap between headlight II and front bumper; 3-Headlight II; 4-Headlight bracket; 5-Front bumper crossbeam; 6-Positioning fixture; 401-First thin plate; 402-Second thin plate; 403-Through hole; 404-Headlight bracket positioning hole; 501-Internal threaded hole; 502-Front bumper crossbeam positioning hole; 601-Positioning rod; 602-Positioning block; 603-Positioning pin; 604-X-direction adjusting shim; 605-Y-direction adjusting shim; 606-Z-direction adjusting shim; 607-Base plate. Detailed Implementation

[0032] It should be noted that in the description of this invention, the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation.

[0033] In this invention, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; a connection can be a mechanical connection or an electrical connection; a link can be a direct connection or an indirect connection through an intermediate medium, and can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0034] A device for positioning headlights on a front bumper crossbeam includes: a headlight bracket 4, a front bumper crossbeam 5, and a positioning fixture 6;

[0035] The headlight bracket 4 consists of two thin plates integrally formed at a 90-degree angle. The first thin plate 401 has multiple through holes 403, and the second thin plate 402 has multiple headlight bracket positioning holes 404, a snap-fit ​​structure, and a hollow structure.

[0036] The front bumper crossbeam 5 is the first crossbeam behind the front bumper of the car, and it is provided with multiple internal threaded holes 501 and multiple front bumper crossbeam positioning holes 502.

[0037] The positioning device 6 includes a base plate 607, on which a plurality of positioning rods 601 are provided, and on which a plurality of positioning blocks 602 are provided. The positioning blocks 602 are connected to the positioning rods 601 through adjusting shims. The positioning blocks 602 are provided with positioning pins 603, which can match the headlight bracket positioning hole 404 and the front bumper beam positioning hole 502 to fix the spatial position of the front bumper beam 5 and the headlight bracket 4.

[0038] Furthermore, the diameter of the internal threaded hole 501 on the front bumper beam 5 is smaller than the diameter of the through hole 403 on the first thin plate 401.

[0039] Furthermore, the positioning block 602, the adjusting shim, and the positioning rod 601 are connected by bolts.

[0040] Furthermore, there are four or more positioning rods 601, each positioning rod 601 has three or more positioning blocks 602, each positioning block 602 is provided with an adjusting shim, and at least one positioning block 602 is provided with a positioning pin 603.

[0041] Furthermore, the substrate 607 is a cuboid with a rectangular top surface. The adjusting shims are divided into an X-axis adjusting shim 604, a Y-axis adjusting shim 605, and a Z-axis adjusting shim 606. The X-axis adjusting shim 604 is perpendicular to the substrate 607 and faces the short side of the top surface of the substrate 607. The Y-axis adjusting shim 605 is perpendicular to the substrate 607 and perpendicular to the X-axis adjusting shim 604. The Z-axis adjusting shim 606 is parallel to the substrate 607.

[0042] Furthermore, the thickness of the adjusting shim is 0.1mm-5mm.

[0043] A method for positioning headlights on a front bumper crossbeam includes the following steps:

[0044] Place the front bumper beam 5 on the positioning fixture 6, and fix the position of the front bumper beam 5 by matching the positioning pin 603 with the positioning hole 502 of the front bumper beam.

[0045] Place the headlight bracket 4 on the front bumper beam 5 and fix the spatial position of the headlight bracket 4 and the front bumper beam 5 by matching the positioning pin 603 with the headlight bracket positioning hole 404.

[0046] By adjusting the thickness of the shims, the headlight bracket 4 and the front bumper beam 5 are positioned in accordance with the standard.

[0047] Use bolts that match the internal threaded holes 501 of the front bumper beam 5 to pass through the through holes 403 on the first thin plate 401 to fix the headlight bracket 4 to the front bumper beam 5. Measure the distance between the headlight bracket 4 and the front bumper beam 5 and make fine adjustments through the through holes 403 on the first thin plate 401 until the distance meets the requirements.

[0048] The adjusting shim can also be a magnetic device that can magnetically attract the positioning rod and positioning block; or a slide rail can be provided on the positioning rod and positioning block, and the adjusting shim is I-shaped so that it can match the slide rail on the positioning rod or positioning block.

[0049] This invention designs two sets of XYZ-oriented adjustable headlight brackets on the front bumper crossbeam and manufactures two types of combined tooling: a positioning tooling for the front bumper crossbeam brackets on the front bumper crossbeam and a positioning tooling for the front bumper crossbeam assembly on the vehicle body. Through this structural and tooling design, because the diameter of the through-hole on the headlight bracket is larger than the internal threaded hole on the front bumper crossbeam, the headlight bracket can be moved using the positioning fixture to minimize error. Ultimately, the overall deviation of the front headlight II mounting point on the front bumper crossbeam relative to the front end of the vehicle can be controlled from ±3mm to within ±1.0mm, ensuring a DTS (Displacement Tolerance) of 2.0±1.2mm, exceeding the industry standard of 2.0±1.5mm.

[0050] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions, and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention, and within the spirit and principles of the present invention, should be included within the scope of protection of the present invention. Furthermore, all content not described in detail in this specification is prior art known to those skilled in the art.

[0051] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

Claims

1. A device for positioning headlights on a front bumper crossbeam, characterized in that, include: The system comprises a headlight bracket, a front bumper crossbeam, and a positioning device. The headlight bracket consists of two thin plates integrally formed at a 90-degree angle. The first thin plate has multiple through holes, and the second thin plate has multiple headlight bracket positioning holes, a snap-fit ​​structure, and a hollow structure. The front bumper crossbeam is the first crossbeam behind the front bumper of the vehicle, and it has multiple internal threaded holes and multiple front bumper crossbeam positioning holes. The positioning device includes a base plate with multiple positioning rods and multiple positioning blocks on the positioning rods. The positioning blocks are connected to the positioning rods via adjusting shims, and each positioning block has a positioning pin that can match the positioning holes of the headlight bracket and the front bumper crossbeam to fix the spatial position of the front bumper crossbeam and the headlight bracket. There are four or more positioning rods, each positioning rod has three or more positioning blocks, each positioning block is equipped with an adjusting shim, and at least one positioning block is equipped with a positioning pin; the top surface of the base plate is a rectangular structure, and the adjusting shims are divided into X-axis adjusting shims, Y-axis adjusting shims, and Z-axis adjusting shims. The X-axis adjusting shims are perpendicular to the base plate and face the short side of the base plate; the Y-axis adjusting shims are perpendicular to the base plate and perpendicular to the X-axis adjusting shims; the Z-axis adjusting shims are parallel to the base plate; the thickness of the adjusting shims is 0.1mm-5mm; the diameter of the internal threaded hole on the front guard beam is smaller than the diameter of the through hole on the first thin plate; the positioning blocks, adjusting shims, and positioning rods are bolted together.

2. A method for positioning a headlight on a front bumper crossbeam using the device described in claim 1, characterized in that, Includes the following steps: Place the front bumper beam on the positioning fixture and fix its position by matching the positioning pins with the positioning holes on the front bumper beam. Place the headlight bracket on the front bumper beam and fix its spatial position by matching the positioning pins with the positioning holes on the headlight bracket. Adjust the thickness of the adjusting shims to make the headlight bracket and front bumper beam positions meet the requirements. Use bolts that match the internal thread holes of the front bumper beam to pass through the through holes on the first thin plate to fix the headlight bracket to the front bumper beam. Measure the distance between the headlight bracket and the front bumper beam and make fine adjustments through the through holes on the first thin plate until the distance meets the requirements.

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