Cockpit Module Tolerance Compensation via Holder
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Solution Overview
Problem
Existing motor vehicle cockpit modules face challenges in achieving a rigid and precise attachment to the vehicle body due to manufacturing tolerances, which can lead to misalignment of critical components like the head-up display and steering column.
Innovation Solution
A cockpit module design where the support tube is connected to the A-pillars and supported by a holder with tolerance compensation elements, allowing for flexible positioning independent of manufacturing tolerances, with additional compensation between the holder and the lower cowl in multiple directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the support tube is rigidly connected to both A-pillars and lower cowl to ensure structural stability, then the rigidity and strength of the cockpit module is improved, but manufacturing tolerances cause misalignment and make precise positioning difficult
Solution Approach 1:
The connection system is segmented into multiple independent connection points: two connections to A-pillars and one connection to lower cowl. This segmentation allows each connection to independently accommodate tolerances while collectively providing stable support.
Solution Approach 2:
The lower cowl connection acts as an intermediary element that compensates for cumulative tolerances from the support tube manufacturing. By providing an additional reference point independent of the support tube, it mediates the positioning accuracy issue.
2Manufacturing precision
If multiple connection points are used to compensate for tolerances, then positioning accuracy is improved, but the device complexity increases
Solution Approach 1:
The lower cowl serves multiple functions: it provides structural support, acts as a reference point for positioning, and compensates for manufacturing tolerances. This multi-functionality reduces the need for separate dedicated components.
Solution Approach 2:
The existing lower cowl structure is utilized to provide positioning reference and support functions, rather than adding dedicated reference components. The structure serves itself by being part of the vehicle body that the cockpit module needs to align with.
3Device complexity
If the head-up display is connected directly to the support tube, then the structure is simplified, but manufacturing tolerances of the support tube cause distortion of the display on the windscreen
Solution Approach 1:
The holder connected to the lower cowl serves as an intermediary mounting structure for the head-up display. This isolates the display from the support tube's manufacturing tolerances, as the lower cowl provides a more stable reference plane.
Solution Approach 2:
The head-up display mounting function is extracted from the support tube structure and placed on a separate holder connected to the lower cowl. This separation removes the display positioning from the tolerance chain of the support tube.
4Manufacturing precision
If centering pins with precise fit are used to attach the cockpit module to the lower cowl, then positioning accuracy is improved, but the assembly process becomes more time-consuming
Solution Approach 1:
The holder is pre-positioned and secured to the lower cowl before final cockpit module installation. This preliminary action establishes the reference position in advance, making the subsequent fitting process faster and easier.
Solution Approach 2:
The receptacle in the cockpit module is designed to fit over the holder that is already installed on the lower cowl. This nested fitting approach allows for quick alignment and secure attachment without complex adjustment procedures.
Data Source
Figure 1
Figure 2
AI summary
The car has a cockpit module supported by a transverse tubular support (1) for the dashboard whose ends are attached to the A-pillars. The central section of the support is attached to a mounting (4) fixed to the windscreen cowl (5), allowing adjustment in the longitudinal direction.