Elastic Cantilever Beam Alignment for Precision Mating
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Solution Overview
Problem
Current manufacturing processes result in significant positional variation and poor fit between mated components due to manufacturing variances, leading to large and varying gaps, misalignment, and potential rattle between components.
Innovation Solution
An elastic cantilever beam alignment system is introduced, featuring first and second male alignment features connected to the components, which interface with corresponding female alignment features, utilizing elastic deformation to achieve precise alignment and pull components together, eliminating play and providing stiffened positional constraint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional male and female location features with clearance are used, then ease of assembly is improved, but manufacturing precision deteriorates due to significant positional variation and gaps
Solution Approach 1:
The patent changes the geometric parameters of the location features by introducing elastic deformation capability. The male location feature includes an elastic element that can deform under load, transforming the rigid clearance-based alignment into a compliant fit that adapts to manufacturing variances while maintaining precision.
Solution Approach 2:
The patent introduces dynamic behavior to the alignment system through elastic deformation. The elastic element in the male location feature can dynamically adjust its position and shape during assembly and operation, allowing the system to adapt to positional variations while maintaining precise alignment.
2Reliability
If clearance is provided between male and female location features, then assembly tolerance is improved, but alignment precision deteriorates leading to large gaps and misalignment
Solution Approach 1:
The patent modifies the physical state of the male location feature by incorporating an elastic element that can change its dimensional parameters under load. This allows the feature to compensate for clearance while maintaining precise alignment through elastic deformation.
Solution Approach 2:
The elastic element acts as an intermediary between the male and female location features. It absorbs the effects of clearance and manufacturing variances, mediating the interaction between the two features to achieve both tolerance and precision simultaneously.
3Strength
If rigid location features are used, then structural strength is improved, but adaptability to manufacturing variances deteriorates causing rattle and poor fit
Solution Approach 1:
The patent introduces parameter change capability through elastic deformation in the male location feature. This allows the rigid structure to dynamically adjust its dimensions and position to accommodate manufacturing variances, eliminating rattle and improving fit while maintaining overall structural strength.
Solution Approach 2:
The patent transforms the static rigid location feature into a dynamic system where the elastic element can adapt its shape and position. This dynamic capability allows the structure to respond to and adapt to manufacturing variances while maintaining strength.
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 with minimal gap (0.0-0.05 mm) between components, eliminating rattle and misalignment, and provides a stiffened positional constraint, averaging out manufacturing variances for a reliable and consistent fit.
Implementation Method 1
The first elastic cantilever beam has a generally non-deformable beam arm on one side of a slot, and an elastically deformable beam arm on the other side of the slot
Data Source
AI summary
An elastic cantilever beam alignment system for the precise mating of first and second components. A first elastic cantilever beam protrudes in parallel from the first component and is elastically over-constrained by two mutually spaced alignment walls of the second component. A second elastic cantilever beam is upstanding in perpendicular relation to the first component and is elastically deformed with respect to a cammed aperture of the second component.