Elastic Tube Alignment System for Vehicular Component Precision
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Solution Overview
Problem
Current alignment systems for vehicular components often suffer from significant positional variation due to manufacturing variances, leading to misalignments that affect the function and aesthetic appearance of assemblies, and require separate features for alignment and fastening, limiting their effectiveness.
Innovation Solution
An elastically averaged alignment system that integrates a deformable alignment and fastening element, where a hollow tube with a thinner wall thickness elastically deforms to align components in multiple directions, providing both alignment and securement through a single element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid alignment features with clearance 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 structure to an elastically deformable structure, changing the physical parameter of stiffness. This allows the alignment feature to deform elastically during assembly to accommodate manufacturing tolerances while maintaining precise alignment, resolving the contradiction between accommodating tolerance and maintaining precision.
Solution Approach 2:
The alignment feature becomes dynamically adaptable by incorporating elastic deformability. The feature can dynamically adjust its position through elastic deformation during the assembly process, allowing it to self-align and compensate for manufacturing variations, thereby improving both alignment precision and positional consistency.
2Adaptability or versatility
If separate alignment features and fastening features are used, then alignment and securement functions are provided, but device complexity increases and effectiveness is limited
Solution Approach 1:
The alignment feature and fastening feature are merged into a single integrated structure. The elastically deformable alignment feature incorporates an internal cavity that receives a fastener, combining both alignment and securement functions into one feature set, thereby reducing device complexity while maintaining versatility.
Solution Approach 2:
The single alignment feature performs multiple functions: it provides alignment through elastic deformation, maintains positioning during assembly, and facilitates fastening through its internal cavity. This multi-functional design eliminates the need for separate alignment and fastening features, improving adaptability while reducing complexity.
3Ease of manufacture
If oversized alignment features with clearance are used, then manufacturing variances are accommodated, but alignment precision deteriorates due to gaps and spacing between mated components
Solution Approach 1:
The alignment feature changes from rigid to elastically deformable, allowing it to dynamically adjust its dimensions through elastic deformation. This enables the feature to accommodate manufacturing tolerances without creating gaps, as the elastic material can deform to fill the clearance and maintain precise alignment between mated components.
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 solution minimizes manufacturing positional variance, ensures precise alignment, and facilitates repeatable assembly and disassembly by using elastically deformable materials that provide an interference fit, thereby enhancing the quality and functionality of component assemblies.
Implementation Method 1
The elastically deformable alignment element portion is configured and disposed to interferingly, deformably and matingly engage the alignment aperture. Portions of the elastically deformable alignment element portion when inserted into the alignment aperture elastically deform to an elastically averaged final configuration
Data Source
AI summary
An elastically averaged alignment system includes a first component having a first alignment member, an attachment element, and a support element, and a second component having a second alignment member, an alignment aperture, and an engagement surface that engages with the support element. The attachment element includes an attachment portion and an elastically deformable alignment element portion. The elastically deformable alignment element portion is configured and disposed to interferingly, deformably and matingly engage the alignment aperture. The attachment portion includes a hollow tube having a first wall thickness, and the elastically deformable alignment element portion includes a hollow tube having a second wall thickness less than the first wall thickness. Portions of the elastically deformable alignment element portion when inserted into the alignment aperture elastically deform to an elastically averaged final configuration that aligns the first alignment member with the second alignment member in at least two planar orthogonal directions.