Elastic Averaging Alignment Features for Precise Press-Fit Assembly
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Solution Overview
Problem
Current assembly methods for vehicle components suffer from significant positional variation due to manufacturing variances, leading to misalignment and poor quality perception, as they rely on predetermined clearance between alignment features that fail to account for size and positional variations.
Innovation Solution
The method involves forming a first member with elastically deformable locating protrusions and a second member with compression features, where the protrusions are inserted in press fit engagement to secure and precisely align the components through the averaging of elastic deformation, allowing for desired stiffness characteristics and larger slot compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If predetermined clearance is provided between alignment features to accommodate manufacturing variances, then components can be freely positioned during assembly, but significant positional variation occurs between mated components leading to misalignment
Solution Approach 1:
The invention changes the physical state of the alignment features from rigid to elastically deformable. The locating protrusions are designed with elastic material properties that allow them to deform during insertion and then return to their original shape, providing both the compliance needed for easy assembly and the precision needed for accurate alignment. This parameter change resolves the contradiction by making the alignment features adaptable to manufacturing variances while maintaining precise positioning.
Solution Approach 2:
The invention introduces dynamic behavior to the alignment features through elastic deformation. The locating protrusions dynamically adjust during the assembly process by deforming elastically to accommodate misaligned components, then maintaining a stable, precisely aligned position once mated. This dynamic adaptation allows the system to transition from a rigid, tolerance-sensitive state to a compliant, precision-maintaining state, resolving the contradiction between ease of assembly and alignment precision.
2Adaptability or versatility
If rigid alignment features with predetermined clearance are used, then manufacturing variances are accommodated, but misalignment occurs affecting function and quality perception
Solution Approach 1:
The invention changes the physical state of the alignment features from rigid to elastically deformable. The locating protrusions are designed with elastic material properties that allow them to deform during insertion and then return to their original shape, providing both the compliance needed for easy assembly and the precision needed for accurate alignment. This parameter change resolves the contradiction by making the alignment features adaptable to manufacturing variances while maintaining precise positioning.
Solution Approach 2:
The elastic deformability of the locating protrusions provides a form of beforehand cushioning against misalignment. The elastic material acts as a buffer that absorbs the shocks of manufacturing variances and positional variations during the assembly process, preventing these variations from translating into final misalignment. This beforehand cushioning ensures reliable alignment despite the presence of manufacturing tolerances.
3Manufacturing precision
If elastic deformation averaging is used to achieve precise alignment, then alignment precision is improved, but the device complexity increases
Solution Approach 1:
The elastic locating protrusions are designed to automatically perform the alignment function through their inherent elastic properties. When the protrusions are inserted into the receiving features, they self-adjust through elastic deformation to accommodate manufacturing variances and achieve precise alignment without requiring external adjustment mechanisms, complex tooling, or additional alignment steps. This self-service approach achieves high alignment precision while minimizing device complexity.
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
This approach ensures precise alignment and desired stiffness characteristics while maintaining acceptable dimensions, addressing the issue of misalignment and variability in existing assembly methods.
Implementation Method 1
the average of the elastic deformation between all of the plurality of locating protrusions and all of the plurality of compression features precisely aligns the first member relative to the second member
Data Source
AI summary
A method of assembly includes forming a first member to include a plurality of elastically deformable locating protrusions extending outward from an exterior surface of the first member. A locating protrusion is an elongate member having an arcuate portion, a first linear leg portion extending from a first arc end, and a second leg portion extending from a second arc end. The method additionally includes forming a second member to include a plurality of elastically deformable compression features. The locating protrusions are inserted in press fit engagement with the plurality of compression features such that the first member and the second member are secured relative to each other and the average of the elastic deformation between all of the plurality of locating protrusions and all of the plurality of compression features precisely aligns the first member relative to the second member.