Compensating Helix Screw for Tolerance Compensation
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Solution Overview
Problem
Existing devices for screwing together components with automatic tolerance compensation are often costly, complex, space-intensive, and have reliability issues due to a large number of parts.
Innovation Solution
A device comprising a screw and a compensating helix with a frictional or positive engagement, where the helix is designed to rotate through a helical pull-through section to fill the joint gap, allowing the screw to be inserted into a threaded hole, minimizing parts and space while ensuring reliable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing devices with automatic tolerance compensation are used, then manufacturing and assembly tolerances can be compensated, but manufacturing costs and device complexity increase due to a large number of parts
Solution Approach 1:
The invention merges the screw and compensating helix into a single integrated component where the helix is formed directly on the screw body. This eliminates the need for separate compensating helix parts and their associated mounting hardware, thereby reducing the total number of parts while maintaining the tolerance compensation function. The helix is created through winding a strip around the screw or by direct forming on the threaded rod, integrating multiple functions into one element.
Solution Approach 2:
The screw component serves multiple functions simultaneously: it provides the threading for joining components, acts as the driving element for the compensating helix, and integrates the compensating helix structure itself. This multi-functionality eliminates the need for separate dedicated compensating mechanism parts, reducing overall device complexity while maintaining reliability.
2Reliability
If existing devices with automatic tolerance compensation are used, then joint gap tolerances can be compensated, but manufacturing costs increase
Solution Approach 1:
By integrating the compensating helix directly onto the screw body through winding or forming processes, the invention eliminates the need for separate manufacturing of individual helix components and their assembly. This integration reduces the total number of manufacturing operations, assembly steps, and quality control checkpoints, thereby lowering overall manufacturing costs while maintaining the tolerance compensation capability.
Solution Approach 2:
The invention allows for easy adjustment of the compensating helix parameters (pitch, diameter, number of turns) by modifying the winding process parameters or forming tool settings. This flexibility enables cost-effective manufacturing across different application requirements without requiring entirely different component designs, reducing tooling and retooling costs.
3Reliability
If existing devices with automatic tolerance compensation are used, then joint gap tolerances can be compensated, but space requirements increase
Solution Approach 1:
The integration of the compensating helix onto the screw body eliminates the need for separate housing or mounting structures that would be required for discrete compensating mechanisms. The compensating function is achieved within the existing screw geometry, thereby reducing the overall volume and space requirements of the assembly while maintaining full tolerance compensation capability.
4Extent of automation
If existing devices with automatic tolerance compensation are used, then automatic compensation can be achieved, but functional reliability decreases due to complexity
Solution Approach 1:
By reducing the number of separate parts and interfaces, the integrated screw-helix design minimizes potential failure points such as loose connections, misalignments, or wear between separate components. The monolithic structure eliminates assembly errors and reduces maintenance requirements, thereby improving functional reliability while maintaining automatic tolerance compensation.
Solution Approach 2:
The compensating helix is designed to automatically perform the tolerance compensation function through its geometric properties and interaction with the joint gap, without requiring external control systems, sensors, or active actuators. This passive self-compensating mechanism reduces complexity and improves reliability by eliminating electronic or mechanical control systems that could fail.
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 solution results in a device with low manufacturing costs, simple design, minimal space requirements, and high functional reliability, effectively compensating for manufacturing and assembly-related tolerances without warping or deforming the components.
Implementation Method 1
The frictional connection and/or positive connection between the screw and the compensating helix is then overcome by driving the screw further
Data Source
Figure 1~4
Figure 5~6
AI summary
A device for screwing together a first component A and a second component B, leaving a gap SP, is described. This device uses a screw 4 and a compensating helix 2 to compensate for tolerances in the gap. The compensating helix 2 can be secured to the screw 4 by friction and/or a releasable positive locking mechanism, and its dimensions are matched to a helical through-section 6 of the first component A. The compensating helix can therefore be rotated by driving the screw through the through-section until it fills the gap to compensate for tolerances. The friction and/or releasable positive locking mechanism is then overcome by further driving of the screw 4, allowing the screw to be inserted into a threaded bore 24 of the second component B to join the two components.