Bracket Assembly Sliding Projections Reduce Insertion Resistance
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Solution Overview
Problem
The existing method for assembling an ECU case to a bracket results in high insertion resistance due to surface-to-surface contact, leading to poor assembly workability.
Innovation Solution
The assembly structure features sliding projections on the bracket's insertion portion that reduce contact area by sliding on opposed wall portions, with a configuration of three contact points to prevent rattling and adjust peak insertion resistance timing, allowing for stable insertion and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface-to-surface contact is used between the insertion portion and opposed pressing portions, then the contact area is large providing stable contact, but the insertion resistance increases leading to poor assembly workability
Solution Approach 1:
The insertion portion is divided into multiple sliding projections (first, second, and third sliding projections) instead of a single continuous surface. This segmentation reduces the contact area between the insertion portion and opposed pressing portions, thereby decreasing insertion resistance while maintaining stable contact through multiple discrete contact points
Solution Approach 2:
Different regions of the insertion portion have different contact characteristics. The sliding projections are positioned at specific locations to create point contacts rather than surface contacts. This local quality change reduces friction and insertion resistance in critical areas while maintaining overall structural stability
2Reliability
If the number of sliding projections is increased to four or more contact points, then rattling prevention is improved, but manufacturing complexity increases due to adjustment requirements
Solution Approach 1:
The sliding projections are arranged asymmetrically with different numbers on each side (one first sliding projection, one second sliding projection on the first side; one third sliding projection on the second side). This asymmetric arrangement achieves effective rattling prevention with only three projections, avoiding the manufacturing complexity that would arise from symmetric four-or-more point arrangements
Solution Approach 2:
Instead of using the minimum two points or excessive four or more points, the invention uses three sliding projections positioned strategically. This partial action approach achieves the necessary stability and rattling prevention without the increased manufacturing complexity associated with four or more adjustment-required contact points
3Ease of operation
If point-sliding is used instead of surface-sliding to reduce insertion resistance, then assembly workability is improved, but rattling occurs due to reduced contact area
Solution Approach 1:
The insertion portion is segmented into multiple sliding projections that create distributed point contacts. While each contact point is small (reducing insertion resistance), the multiplication of contact points across different locations provides sufficient stability to prevent rattling, resolving the contradiction between point-contact advantages and stability requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly reduces insertion resistance, improves assembly workability by distributing the force effectively, and prevents rattling, ensuring a stable assembly process.
Implementation Method 1
the sliding projections slide on the opposed wall portions at a time of the insertion... the contact area can be reduced and the insertion resistance can be greatly reduced
Data Source
AI summary
An object is to reduce sliding resistance when a bracket is assembled to a case, thereby improving assembly workability. In an assembly structure for assembling a bracket to a case, the case has opposed wall portions opposed to each other on the outer peripheral side surface thereof, and the bracket has a plate-shaped insertion portion to be inserted in a predetermined direction into an opposition clearance between the opposed wall portions, and three sliding projections protruding from both side surfaces of the insertion portion which are to be opposed to the opposed wall portions, so that the sliding projections slide on the opposed surfaces of the opposed wall portions at the time of the insertion. The sliding projections are provided so as to appear alternately, in the predetermined direction, on both side surfaces of the insertion portion.