Datum Pin Assembly for Jig-Free Roller Alignment
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Solution Overview
Problem
The existing methods for aligning a roller assembly with a door bracket in motor vehicles often require a jig, which can be complicated or impractical to use, necessitating an improved alignment system without a jig.
Innovation Solution
A bracket assembly with fastener holes, pin holes, and datum pins, along with an alignment piece and movable datum pins, allows for precise alignment and attachment of the roller assembly to the door panel without the need for a jig, using a combination of alignment holes and movable datum pins to ensure accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a jig is used for alignment, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the alignment function from the complex jig system and implements it through simple datum pins integrated directly into the bracket assembly. The datum pins are removed from the door panel and incorporated into the bracket, eliminating the need for external jigs while maintaining alignment precision.
Solution Approach 2:
The bracket assembly performs its own alignment function through integrated datum pins, eliminating the need for separate alignment tools or jigs. The bracket is self-sufficient for alignment purposes by incorporating the reference features directly into its structure.
2Measurement precision
If a jig is used for alignment, then alignment precision is improved, but ease of operation deteriorates
Solution Approach 1:
The alignment function is extracted from the door panel and transferred to the bracket assembly through integrated datum pins. This eliminates the need for complex jig operations and makes the alignment process simpler and more straightforward.
Solution Approach 2:
Instead of using the door panel as the reference for alignment, the patent inverts the approach by making the bracket assembly the reference through its integrated datum pins. This reversal simplifies the operation by eliminating the need for external alignment tools.
3Ease of operation
If oversized bolt holes are used, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces the mechanical tolerance accommodation method (oversized holes) with a precision alignment system using datum pins. The datum pins provide precise positioning, eliminating the need for oversized holes while maintaining ease of assembly through the self-aligning feature.
Data Source
AI summary
A system and method for assembling a door to a motor vehicle is disclosed including a bracket assembly that includes a bracket having a first pair of holes and a second pair of holes, and weld nuts welded to the bracket, the weld nuts being aligned with the first pair of holes. The system further includes an alignment piece having first and second alignment holes, the first alignment hole corresponding to a first of the second pair of holes of the bracket, the second alignment hole corresponding to a second of the second pair of holes of the bracket, datum pins inserted through the first and second alignment holes and the second pair of holes in the bracket, and a roller assembly fixedly attached to the bracket.