Clip-On Spacer for Front End Module Gap Compensation
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Solution Overview
Problem
Existing compensation elements used in motor vehicle production to accommodate manufacturing tolerances between the front end module and bumper beam bracket are complex and do not fill the gap until the bolt is shot, leading to potential rocking of the front end module during assembly, affecting fit and finish.
Innovation Solution
A clip-on spacer with a retainer and spacer element providing a compression joint or friction fit, comprising a receiver and tang with a bolt guide, and resilient clip feature to fill the gap before bolt insertion, preventing rocking and ensuring proper fit and finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complicated compensation element comprising multiple components is used to accommodate manufacturing tolerances, then the gap compensation capability is improved, but the device complexity increases
Solution Approach 1:
The compensation element is divided into two separate components: a retainer that attaches to the bolster carrier, and a spacer element that provides the gap compensation. This segmentation allows each component to be optimized independently and simplifies the overall assembly process.
Solution Approach 2:
The spacer function is extracted from the complex compensation element and implemented as a separate spacer element with a simple frustoconical shape. This extraction eliminates the need for multiple interacting components while maintaining the gap compensation capability.
2Ease of operation
If the compensation element is designed to fill the gap only after bolt installation, then the assembly process is simplified, but the front end module stability deteriorates due to rocking
Solution Approach 1:
The retainer is preliminarily attached to the bolster carrier before the spacer element is installed. This preliminary action ensures that the spacer is already in position to prevent rocking when the front end module is loaded, while still allowing for simple subsequent assembly of the spacer element itself.
3Ease of manufacture
If a simple two-component device is used for gap filling, then the manufacturing cost is reduced, but the connection reliability may worsen
Solution Approach 1:
The frustoconical shape of the spacer element creates a changing contact surface area along its length, providing progressive engagement with the retainer. This geometric parameter change ensures reliable connection while maintaining simple manufacturing of both components.
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
The clip-on spacer simplifies the assembly process by providing a stable connection between the front end module and bumper beam, ensuring controlled fit and finish without requiring changes to existing components, and is cost-effective to produce.
Implementation Method 1
a resilient clip feature to secure the spacer element to the bolster carrier
Implementation Method 2
a compression joint or friction fit is provided between the receiver and the tang
Data Source
AI summary
A clip-on spacer includes a retainer having a receiver and a resilient clip and a spacer element having a tang and a bolt guide. A front end module includes a bolster carrier, a grille carried on the bolster carrier and a clip-on spacer fixed to the bolster carrier.