Counter-Rotating Adjustment Bracket for Variable Assembly Gaps
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Solution Overview
Problem
Variability in assembly tolerances between parts, such as vehicle bumpers and fenders, due to non-parallel planes during manufacturing, leads to challenges in securing a robust connection, necessitating an adjustable bracket that can accommodate varying margins.
Innovation Solution
An adjustment bracket comprising two tapered discs that can counter-rotate at an equal amount, allowing for adjustment and locking into a position to accommodate varying gaps between parts, utilizing guide slots and a disc position adjustment mechanism to achieve precise alignment and secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional rigid brackets are used to connect parts, then manufacturing and assembly are simple, but assembly tolerances cannot accommodate non-parallel planes and variable margins between parts
Solution Approach 1:
The bracket incorporates two discs that can rotate relative to each other around a central axis, transforming a static rigid structure into a dynamic adjustable one. This rotational capability allows the bracket to adapt to various margin variations between parts while maintaining structural integrity
Solution Approach 2:
The relative position between the two discs is adjusted by changing the angular parameter (rotation angle) around the central axis. This parameter change modifies the effective thickness and orientation of the bracket body, enabling accommodation of different assembly tolerances without redesigning the entire bracket
2Adaptability or versatility
If adjustable mechanisms are added to accommodate margin variability, then adaptability improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The bracket is segmented into two separate discs that can be manufactured independently and then assembled together. This segmentation simplifies the manufacturing of each individual disc while providing the capability for relative adjustment through their rotational connection
Solution Approach 2:
The use of circular discs with rotational symmetry provides a smooth, continuous adjustment mechanism. The circular geometry naturally facilitates rotation and allows for precise angular positioning without complex machining requirements
3Reliability
If the bracket structure is made more complex to adjust for tolerance variations, then connection reliability improves, but production time and cost increase
Solution Approach 1:
The two-disc rotational mechanism is designed to be self-adjusting within the assembly process. The adjustability is inherent in the mechanism itself, eliminating the need for external adjustment tools or complex alignment procedures that would slow down production
Data Source
AI summary
An adjustment bracket used to adjust a space between a first part and a second part is provided. The adjustment bracket comprises a cylindrical adjustment body including a first disc and a second disc. The first and the second discs are formed by cutting the adjustment body into two equal halves along a slanted surface. The first disc and the second disc are capable of counter rotating at an equal amount at an opposite direction, and the adjustment body has a substantially same thickness around its circumference at a home position, and has a varied thickness when the first and second discs rotates along a central axis away from the home position.