Vehicle Bumper Cross-Member Coupling for Easier Assembly
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Solution Overview
Problem
Existing land vehicle assembly processes are cumbersome and ergonomically challenging due to the difficulty in aligning screw holes for attaching front and rear bumpers to wings, requiring numerous manipulations and operations, especially with large bumpers and dimensional variations.
Innovation Solution
A cross member is integrated into the vehicle's front or rear structure, with the bumper featuring internal coupling pieces that attach to this member, allowing for easier alignment and secure attachment to the wings, simplifying the assembly process and improving ergonomics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections are used to attach the bumper to the wings and structure, then the bumper can be securely fixed, but the assembly process becomes complex and time-consuming due to alignment difficulties
Solution Approach 1:
The patent introduces alignment pins as intermediary elements that mediate between the bumper and the wings/structure. These pins serve as temporary guides that automatically align the screw holes, eliminating the need for manual alignment while maintaining secure attachment. The alignment pins are removed after screwing, having fulfilled their mediating function.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the alignment pins in the wings and structure before attempting to attach the bumper. This preliminary placement of alignment features ensures that when the bumper is brought into position, the screw holes are already aligned, eliminating the time-consuming alignment step during actual assembly.
2Reliability
If numerous screw connections are used to ensure secure bumper attachment, then the structural integrity is improved, but the number of manipulation operations increases
Solution Approach 1:
The alignment pins act as intermediaries that simplify the operation of securing the bumper. By providing automatic alignment, they reduce the skill level and effort required for the screwing operation, making the process easier while maintaining the necessary number of screw connections for reliable attachment.
Solution Approach 2:
The preliminary placement of alignment pins prepares the assembly in advance, so that when the technician performs the screwing operation, all that is required is straightforward fastening without the added complexity of alignment. This separates the alignment function from the fastening function, simplifying the actual operation.
3Manufacturing precision
If the bumper is held in position manually during assembly, then alignment can be achieved, but the ergonomic quality deteriorates due to the large size and weight of the bumper
Solution Approach 1:
The alignment pins serve as mechanical intermediaries that replace manual holding and positioning operations. The technician no longer needs to physically support and align the large bumper; instead, the pre-installed pins provide the positioning function, dramatically improving ergonomics while maintaining positioning precision.
Solution Approach 2:
The alignment pins enable the bumper to self-align and self-position when brought into assembly position. The bumper essentially positions itself relative to the wings and structure through the guidance provided by the pins, eliminating the need for manual positioning effort.
4Manufacturing precision
If the screw holes in the wings and bumper are aligned manually, then proper screwing can be achieved, but the complexity of the assembly process increases due to dimensional variations
Solution Approach 1:
The alignment pins act as intermediaries that absorb and compensate for dimensional variations between the bumper, wings, and structure. By providing a fixed reference geometry, the pins ensure consistent alignment regardless of manufacturing tolerances, while keeping the assembly process simple and repeatable.
Data Source
Figure 1
AI summary
A land vehicle (V) comprises a structure (SV) including a front or rear portion (PV) to which right and left wings (AV) are securely attached, and a bumper (PC) also securely attached to the wings (AV). This front or rear portion (PV) of the structure (SV) comprises a cross-beam (TC) extending in a transverse direction of the vehicle (V) from right to left, and the bumper (PCV) comprises an inner face (FI) provided with at least one coupling part (PDC) coupled to this cross-beam (TC).