Detachable Container Connection Layout for Tolerance Compensation
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Solution Overview
Problem
Existing connection systems for attaching lining elements to container walls require precise manual assembly and disassembly, are complex, and fail to compensate for manufacturing or material-related tolerances, especially in large containers like IBCs, necessitating high automation tolerance requirements.
Innovation Solution
A connection system with two pairs of connection sections allowing translational freedom in orthogonal directions to compensate for manufacturing tolerances, featuring a positive and detachable connection that fixes parts in one plane direction while allowing compensation in the orthogonal direction, preventing movement in the normal direction, and utilizing locking geometries and handling elements for automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection systems are used to attach lining elements to container walls, then the lining element can be positioned and fixed, but precise manual assembly and disassembly are required, increasing complexity and time consumption
Solution Approach 1:
The connection system is divided into multiple independent connection pairs, each responsible for a specific directional constraint. This segmentation allows each connection pair to be simple in design while collectively providing precise positioning and easy assembly through modular installation
Solution Approach 2:
The connection pairs incorporate movable elements that allow automatic adjustment during assembly. The dynamic mechanism enables the connection system to self-align and compensate for tolerances without requiring precise manual positioning, reducing assembly complexity while maintaining reliability
2Manufacturing precision
If conventional connection systems are used, then the lining element can be attached to the wall, but manufacturing tolerances of +/- 0.5 - 1.0 mm for injection-molded containers and +/- 6 mm for foamed interiors cannot be compensated, requiring high automation tolerance requirements
Solution Approach 1:
The connection system incorporates adjustable geometric parameters that allow it to adapt to varying manufacturing tolerances. The connection pairs can accommodate dimensional variations through built-in adjustment mechanisms, enabling the system to maintain precise connection across different container sizes and materials without requiring tight tolerance control
Solution Approach 2:
The connection system addresses tolerance issues by introducing additional degrees of freedom in specific directions. Each connection pair allows movement in one direction while constraining others, effectively compensating for manufacturing variations in three-dimensional space through dimensional accommodation
3Strength
If permanent connection systems (glued or welded) are used, then the connection is resilient and strong, but disassembly is prevented, preventing separate washing or cleaning of outer and inner packaging units
Solution Approach 1:
The connection system uses multiple separate connection pairs instead of a single permanent bond. Each connection pair can be independently opened, allowing the inner packaging unit to be removed for cleaning while maintaining strong connection during use. This segmented approach provides both strength and disassembly capability
Solution Approach 2:
The connection pairs incorporate movable locking mechanisms that transition between locked (strong connection) and unlocked (disassembly) states. This dynamic design maintains strong connection strength during operation while enabling easy disassembly for cleaning by simply actuating the release mechanism
4Ease of operation
If reversible connection systems (screws, clips, connectors) are used, then disassembly is enabled, but assembly and disassembly require several individual steps and manual interaction, reducing productivity
Solution Approach 1:
Multiple connection functions are merged into integrated connection pairs that can be assembled and disassembled as single units. The design combines positioning, locking, and releasing functions into unified mechanisms that can be operated in one motion, increasing assembly speed while maintaining ease of disassembly
Solution Approach 2:
The connection pairs are pre-configured with alignment features and default positioning that guide automatic assembly. The preliminary design of the connection geometry enables robots to assemble the units quickly without complex programming or multiple adjustment steps, while the release mechanism remains simple for disassembly
Data Source
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AI summary
A connection system (2) for the precise and detachable connection of two parts that are manufactured in different ways and have different manufacturing tolerances, preferably an outer, preferably injection-molded, packaging unit (12) and an inner, preferably foam-made, packaging unit (16). With a first connection pair (18) consisting of a first connection section (22; 122) connected or connectable to one part and a second connection section (24; 124) connected or connectable to the other part, and a second connection pair (20) consisting of a first connection section (22; 122) connected or connectable to one part and a second connection section (24; 124) connected or connectable to the other part.The first connection pair (18) can form a positive and detachable connection that allows one translational degree of freedom in the x-direction and prevents translational degrees of freedom in the y- and z-directions. The second connection pair (20) can form a positive and detachable connection that allows one translational degree of freedom in the y-direction and prevents translational degrees of freedom in the x- and z-directions.