Elastic Tube Alignment System for Class A Finish
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current component mating processes using 2-way and 4-way male and female alignment features result in significant positional variation and play, leading to irregular and unbalanced fits, which are unacceptable for a Class A finish.
Innovation Solution
An elastic tube alignment system where geometrically separated elastic tube features on one component correspond with aperture features on another, allowing for elastic deformation to accommodate manufacturing variances, providing precise alignment through elastic averaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If clearance is provided between male and female alignment features to accommodate manufacturing variances, then the mating process becomes smoother and easier, but significant positional variation and float occur resulting in poor fit and unacceptable alignment
Solution Approach 1:
The alignment system transitions from static rigid alignment features to dynamic elastic alignment features. The male alignment feature includes an elastic element that can deform elastically during mating, allowing the system to adapt to manufacturing variances dynamically while maintaining precise alignment. The elastic element deforms to accommodate clearance variations, eliminating float while preserving smooth mating operation.
Solution Approach 2:
The system changes the physical state of the alignment feature by introducing elasticity. The male alignment feature is designed with an elastic element whose stiffness parameter is specifically selected to provide the desired balance: soft enough to deform and accommodate manufacturing tolerances for smooth mating, but stiff enough to maintain precise alignment when loaded. This parameter optimization resolves the contradiction between ease of operation and alignment precision.
2Adaptability or versatility
If rigid male alignment features are used with clearance to female features, then manufacturing variances are accommodated, but considerable float occurs between features leading to misalignment
Solution Approach 1:
The alignment system transitions from static rigid alignment features to dynamic elastic alignment features. The male alignment feature includes an elastic element that can deform elastically during mating, allowing the system to adapt to manufacturing variances dynamically while maintaining precise alignment. The elastic element deforms to accommodate clearance variations, eliminating float while preserving smooth mating operation.
Solution Approach 2:
The system replaces the traditional rigid mechanical alignment system with an elastic mechanical system. Instead of relying on rigid geometric constraints that create float when clearance is provided, the invention uses elastic deformation to achieve both tolerance accommodation and precision alignment. The elastic element substitutes for the rigid mechanical connection, providing adaptability without sacrificing accuracy.
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 achieves precise alignment with minimal play, ensuring a smooth and effortless mating process while eliminating manufacturing variance and float, resulting in a perfect Class A finish.
Implementation Method 1
the elastic tube alignment features have a diameter exceeding a cross-section of the aperture alignment features... whereby elastic deformation occurs as each elastic tube alignment feature is received into its respective aperture alignment feature
Data Source
AI summary
An elastic tube alignment system for the mating of components utilizing the principle of elastic averaging. A plurality of geometrically separated elastic tube (male) alignment features are disposed on a first component, while a plurality of one-to-one corresponding aperture (female) alignment features are provided on a second component. During the mating of the components, each elastic tube and its respective aperture provide elastic deformation, which, on average, precisely aligns the components.