Bump Stop Assembly with Closure Gauge for Door Alignment
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Solution Overview
Problem
The adjustment of bump stops in vehicle doors to ensure correct alignment and prevent rattling is unreliable and tool-restricted, leading to inconsistent results due to manual adjustment and limited access when the door is closed.
Innovation Solution
A bump stop assembly with a door closure gauge and color-coded closure pads that determine the required thickness by measuring protrusion, allowing for precise alignment and adjustment without visible color when assembled, using a thread for coupling and a fir tree connector for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of the bump stop is performed by hand, then the adjustment process is simple and requires no special tools, but the adjustment results are unreliable and inconsistent
Solution Approach 1:
A gauge tool is introduced as an intermediary device between the bump stop and the door frame. The gauge includes a measurement scale that directly contacts the door frame when the door is closed, providing an objective reference for determining the correct bump stop thickness, thereby eliminating subjective judgment and ensuring consistent adjustment results.
Solution Approach 2:
The manual estimation process is replaced with a mechanical measurement system. The gauge tool mechanically transfers the distance from the door frame to the bump stop location, allowing for precise measurement and selection of the appropriate bump stop thickness based on objective data rather than subjective assessment.
2Measurement precision
If the door is closed to adjust the bump stop, then the actual gap between door and door frame can be measured, but access to the bump stop is restricted preventing use of tools or aids
Solution Approach 1:
The adjustment system is segmented into two parts: a gauge tool that can be inserted through the closed door to measure the gap, and a separate selection process for choosing the appropriate bump stop thickness. This allows measurement to be performed when the door is closed while keeping the actual bump stop adjustment accessible when the door is open.
Solution Approach 2:
The gauge serves as an intermediary that bridges the gap between the restricted measurement location (inside closed door) and the adjustment location (bump stop). It transfers the measurement information out from the confined space where the door is closed, enabling accurate measurement without requiring direct access to the bump stop during the measurement phase.
3Manufacturing precision
If multiple bump stop thicknesses are used to achieve correct alignment, then precise adjustment can be obtained, but the selection process becomes more complex
Solution Approach 1:
Different bump stop thicknesses are color-coded to correspond with specific measurement ranges on the gauge. This visual coding system simplifies the selection process by allowing technicians to quickly identify the correct bump stop thickness based on the gauge reading, eliminating the need to compare numerical measurements with multiple product specifications.
Solution Approach 2:
The bump stop selection is transformed from a numerical parameter matching task to a visual parameter matching task. By associating specific thickness parameters with distinct color codes, the system changes the selection criterion from reading and interpreting measurements to simply matching colors, thereby reducing selection complexity while maintaining precision.
Data Source
AI summary
A bump stop assembly is provided for an access door. The assembly comprises a bump stop configured to couple to the access door or a door frame and a door closure gauge movably coupled to the bump stop. A closure pad couples the bump top to one of the door frame or the access door. The closure pad engages the other side of the access door and door frame when the door is closed. The thickness of a selected closure pad is determined based upon the extent that the door closure gauge protrudes relative to the bump stop.