Elastic Front Module Support for Tolerance Compensation
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Solution Overview
Problem
The assembly of front modules in motor vehicles is hindered by large dimensional tolerances in the vehicle body shell, leading to fitment difficulties and impaired joint patterns between the bumper, headlight unit, and hood.
Innovation Solution
A support system for the front module featuring elastic elements connected to the chassis and brackets, which deform and are fixed in place upon hood closure, allowing for tolerance compensation and maintaining the deformed position through screw connections, ensuring a high-quality joint pattern despite varying tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid support parts and brackets are used for mounting the front module, then structural strength and stability are ensured, but dimensional tolerances of the body shell cause fitment difficulties and impaired joint patterns
Solution Approach 1:
The support system changes the physical state of the elastic elements from rigid to flexible, allowing them to deform and adapt to dimensional variations in the body shell. This parameter change enables the system to accommodate tolerances while maintaining structural integrity.
Solution Approach 2:
The patent employs elastic elements as flexible components between the support part and brackets, allowing these elements to deform and compensate for dimensional tolerances in the body shell, thereby ensuring proper fitment of the front module components.
2Manufacturing precision
If elastic elements are used to compensate for dimensional tolerances, then joint pattern precision is improved, but the support structure becomes more complex
Solution Approach 1:
The support structure transitions from a static rigid configuration to a dynamic system where elastic elements can deform and adapt. This dynamic capability allows the structure to self-adjust to dimensional variations without requiring complex adjustment mechanisms.
Solution Approach 2:
The elastic elements automatically compensate for dimensional tolerances through their inherent elasticity, eliminating the need for complex adjustment mechanisms or additional components. The system self-adjusts to ensure proper fitment.
3Manufacturing precision
If multiple adjustment mechanisms are added to accommodate dimensional tolerances, then assembly precision is improved, but assembly time and complexity increase
Solution Approach 1:
The elastic elements automatically compensate for dimensional tolerances through their inherent elasticity, eliminating the need for complex adjustment mechanisms or additional components. The system self-adjusts to ensure proper fitment.
Solution Approach 2:
The elastic elements are pre-configured to deform and accommodate dimensional variations before final assembly is completed. This preliminary adaptation simplifies the assembly process and reduces adjustment time.
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 elastic support system effectively compensates for dimensional tolerances, eliminating complex adjustments during assembly and ensuring a precise fit between the bumper, headlight unit, and hood, even with millimeter-range variations in the vehicle body shell.
Implementation Method 1
the elastic elements allow for tolerance compensation during the installation of the front module... the elastic elements comprise a support surface for the hood of a motor vehicle so that the deformation forces act upon the elastic elements when the hood is closed
Data Source
AI summary
The invention relates to a support for a front module of a motor vehicle comprising a first support part for connection to a chassis of the motor vehicle and left and right brackets, wherein the left and right brackets are configured to receive a headlight unit and for connection to a bumper of the motor vehicle, respectively, wherein the left and right brackets with the left and right elastic elements are connected to the first support part, and comprising structure for fixing the elastic elements relative to the chassis when the elastic elements have assumed an assembly position following elastic deformation.