Bracket Pocket Dimensional Verifier Tool for Vehicle Suspension
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Solution Overview
Problem
Current methods for verifying the dimensions of bracket pockets in vehicle suspension systems, such as those used in CMMs, are costly and time-consuming, requiring extensive computational measurements that can take hours to complete.
Innovation Solution
A manual bracket pocket dimensional verifier tool comprising end exterior sub-assemblies, an intermediate sub-assembly with an extension rod receiving feature, and a method for assembling these tools within lower control arm bracket pockets to determine and register center points, allowing for faster and more cost-effective dimensional verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated coordinate measurement machines (CMM) are used to verify bracket pocket dimensions, then measurement precision is improved, but productivity deteriorates due to hours-long verification times
Solution Approach 1:
The verification tool is divided into multiple sub-assemblies (first end exterior sub-assembly, second end exterior sub-assembly, and intermediate sub-assembly) that can be independently positioned and adjusted. Each sub-assembly targets specific bracket pocket features, allowing for parallel measurement operations and reducing total verification time while maintaining precision.
Solution Approach 2:
The intermediate sub-assembly acts as a mediator connecting the first and second end exterior sub-assemblies. It includes an extension rod receiving feature that establishes a reference relationship between the two ends, enabling accurate dimensional verification without requiring complex automated coordinate systems.
2Measurement precision
If automated CMM systems are deployed for bracket pocket verification, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The verification tool is designed to be self-positioning and self-calibrating within the bracket pocket. The end exterior sub-assemblies insert into cam slots and lock against bracket walls, automatically establishing measurement references without requiring external automated positioning systems or complex setup procedures.
Solution Approach 2:
The manual verification tool replaces expensive, complex automated CMM equipment with a simpler, more affordable manual device. While the tool has limited reuse across different bracket designs, it provides cost-effective verification for specific bracket pocket configurations without the high capital investment required for automated systems.
3Manufacturing precision
If extensive three-dimensional coordinate measurements are performed, then manufacturing precision verification is improved, but loss of time increases
Solution Approach 1:
The verification tool focuses on measuring only the critical dimensions and center points of bracket pockets rather than performing exhaustive three-dimensional coordinate measurements of all features. By targeting specific key parameters (center points, distances between opposing pockets), it achieves sufficient manufacturing precision verification in a fraction of the time required for complete CMM scanning.
Data Source
AI summary
Methods to use a tool for dimensional verification of a vehicle frame suspension system bracket pocket having first and second cam slots, the tool including a first sub-assembly configured for insertion through and registration of the first cam slot; a second sub-assembly configured for insertion through and registration of the second cam slot; and an intermediate sub-assembly disposed between and attachable to the first and second sub-assemblies via a shaft, the intermediate sub-assembly including an extension rod receiving feature defining at least one extension rod receiving aperture; wherein the sub-assemblies lock against the bracket walls to define a horizontal center axis and are adjustable to determine and register a center point along an intersecting vertical center axis between the first and second cam slots that is alignable with the at least one extension rod receiving aperture.