Elastically Deformable Alignment System for Six-Way Precision
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Solution Overview
Problem
Current alignment systems for vehicular components often result in significant positional variation due to manufacturing variances, leading to misalignment and quality issues in assemblies, as they rely on oversized or undersized alignment features that do not provide precise six-way alignment.
Innovation Solution
An elastically averaged alignment system that incorporates elastically deformable alignment elements to engage with corresponding features, allowing for precise six-way alignment by averaging the elastic deformation across multiple orthogonal directions, thereby minimizing manufacturing positional variance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional oversized or undersized alignment features are used, then manufacturing tolerance is accommodated, but alignment precision deteriorates due to significant positional variation between mated components
Solution Approach 1:
The alignment feature transitions from a rigid fixed dimension to an elastically deformable element whose effective engagement parameter changes dynamically. The elastic alignment element deforms to accommodate manufacturing variations in the mating alignment feature, transforming the engagement from a fixed clearance fit to a controlled elastic deformation process that maintains precise alignment throughout the deformation range
Solution Approach 2:
The alignment system transitions from static rigid alignment features to dynamic elastically deformable elements. The elastic alignment element can deform and recover, allowing the system to adapt to varying manufacturing tolerances while maintaining consistent alignment precision. The element's ability to deform elastically creates a dynamic response to manufacturing variations rather than a static tolerance accumulation
2Ease of operation
If clearance is provided between alignment features to allow free movement, then ease of assembly is improved, but alignment precision deteriorates due to positional variation and gaps
Solution Approach 1:
The engagement parameter transitions from a fixed clearance distance to a dynamic elastic deformation parameter. The elastic alignment element provides just enough deformation to eliminate gaps while maintaining ease of assembly through its flexible engagement. The parameter changes from a static clearance value to a controlled elastic deformation that adapts to the specific mating feature
Solution Approach 2:
The elastic alignment element acts as an intermediary between the rigid component structures. It mediates the interaction by deforming to bridge gaps and accommodate variations, providing both the compliance needed for easy assembly and the precision needed for accurate alignment. The intermediary element transforms the interaction from direct rigid contact to controlled elastic engagement
3Strength
If rigid alignment features are used, then structural stiffness is maintained, but alignment precision deteriorates due to inability to compensate for manufacturing variances
Solution Approach 1:
The alignment feature's effective parameter changes from a fixed rigid dimension to a controlled elastic deformation parameter. The elastic element maintains structural stiffness through its material properties and geometry while its engagement parameter dynamically adjusts to compensate for manufacturing variations, achieving both stiffness and precision simultaneously
Solution Approach 2:
The system transitions from static rigid alignment to dynamic elastic alignment while maintaining overall structural stiffness. The elastic alignment element provides localized flexibility for precision alignment without compromising the global structural stiffness of the assembled components. The dynamic deformation is confined to the alignment element itself
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 system ensures precise alignment and retention of components, reducing manufacturing variance and improving assembly quality by providing a repeatable and interference-fit based alignment mechanism that enhances the stiffness and NVH characteristics of the assembly.
Implementation Method 1
Portions of the third and fourth elastically deformable alignment elements when engaged with respective ones of the first and second alignment features elastically deform to an elastically averaged final configuration that aligns the first component relative to the second component
Implementation Method 2
A respective one of the third elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with a respective one of the first alignment feature
Data Source
AI summary
An elastically averaged alignment system includes a first component having first and second alignment features, and a second component having third and fourth elastically deformable alignment elements. The first and second components are laterally slidably engageable with each other. The third elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with the first alignment feature. The fourth elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage with the second alignment feature. Portions of the third and fourth elastically deformable alignment elements when engaged with respective ones of the first and second alignment features elastically deform to an elastically averaged final configuration that aligns the first component relative to the second component in six orthogonal directions by averaging the elastic deformation of the respective elastically deformable alignment elements.