Adjustable Plunger for Vehicle Flap Flush Fit
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Solution Overview
Problem
Manufacturing tolerances often result in offsets between vehicle flaps and surrounding components, necessitating costly rework or component replacement to ensure a flush fit, which affects both aesthetics and aerodynamics.
Innovation Solution
A vehicle flap module with an adjustable plunger and tappet system, where the tappet has a thread for attachment to the vehicle hatch, allowing the length of the plunger to be adjusted to align the vehicle flap seamlessly with the surrounding components, preventing offsets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vehicle flap modules are manufactured with standard tolerances, then production cost and time are reduced, but offsets occur between the vehicle flap and surrounding components resulting in poor flush fit
Solution Approach 1:
The plunger is designed with adjustability, allowing its position to be dynamically changed during assembly to compensate for manufacturing tolerances. This enables the vehicle flap to achieve a flush fit with surrounding components without requiring high-precision manufacturing, thereby resolving the contradiction between manufacturing precision and ease of manufacture
Solution Approach 2:
The length of the plunger protruding beyond the vehicle flap is made variable through the threaded connection with the tappet. By changing the plunger's effective length parameter, the system can accommodate different tolerance variations and achieve proper alignment, eliminating the need for costly rework while maintaining production efficiency
2Measurement precision
If the plunger length is made adjustable via threaded connection, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The threaded connection serves multiple functions: it provides the adjustment mechanism for plunger length, enables fine-tuning of alignment, and allows for simple installation and removal. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity while achieving high alignment precision
Data Source
Figure 1~2
Figure 3
AI summary
A vehicle flap module comprising a vehicle flap (1) and a cover pot, wherein the vehicle flap (1) is pivotably connected to the cover pot so that the vehicle flap (1) can be opened and closed relative to the cover pot, wherein the vehicle flap (1) has a plunger (2) and the cover pot has an actuator for receiving the plunger (2), so that the plunger (2) is received in the actuator when the vehicle flap (1) is closed, wherein the length of the plunger (2) projecting beyond the vehicle flap (1) is adjustable.