Elastically Averaged Alignment System for Automotive Assembly
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Solution Overview
Problem
Current alignment systems for vehicular components, such as automotive parts, face significant positional variations due to manufacturing tolerances, leading to misalignments that affect the function and aesthetic quality of assemblies, and lack the capability for both coarse and fine alignment.
Innovation Solution
An elastically averaged alignment system comprising deformable alignment members and elements that engage to establish a predetermined position by elastic deformation, allowing for both coarse and fine alignment of components through a method involving the engagement and shifting of alignment members and elements to average out positional variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional rigid alignment features with clearance are used, then manufacturing tolerances are accommodated, but positional variation and misalignment between components occur
Solution Approach 1:
The patent changes the physical state of the alignment elements from rigid to elastically deformable. The alignment elements are made of elastomeric material that can deform elastically to accommodate positional variations while maintaining precise alignment. This parameter change allows the system to simultaneously accommodate manufacturing tolerances and achieve high alignment precision.
Solution Approach 2:
The alignment system transitions from a static rigid connection to a dynamic elastic connection. The elastomeric alignment elements can deform and adapt during the assembly process, allowing the system to dynamically adjust to positional variations and achieve optimal alignment. The elastic deformation capability enables the system to absorb misalignments while maintaining precise component positioning.
2Manufacturing precision
If a precise alignment system is provided, then alignment precision is improved, but the system cannot provide both coarse and fine alignment capabilities
Solution Approach 1:
The alignment system is segmented into multiple elastomeric alignment elements that work together to provide both coarse and fine alignment. The plurality of alignment elements distributed across the component interfaces enable the system to handle both gross positional adjustments and precise fine-tuning simultaneously, providing versatile alignment capabilities across multiple degrees of freedom.
Solution Approach 2:
The elastomeric material properties enable the alignment elements to exhibit both compliant behavior for coarse alignment and precise elastic recovery for fine alignment. The material's elastic characteristics allow it to deform under load for coarse positioning and then precisely return to its original shape for fine alignment, providing dual alignment capabilities in a single element type.
3Manufacturing precision
If multiple alignment features are used to reduce positional variation, then alignment precision is improved, but the complexity of the alignment system increases
Solution Approach 1:
The patent merges multiple alignment functions into a single type of elastomeric alignment element. Instead of using different rigid features for different alignment purposes, the elastomeric elements perform multiple functions including positioning, accommodating tolerances, and providing both coarse and fine alignment. This consolidation reduces the variety of components needed while maintaining high alignment precision.
Solution Approach 2:
Changing the material parameter from rigid to elastomeric simplifies the alignment system design. The elastic properties of the material inherently provide tolerance accommodation and alignment precision without requiring complex mechanical adjustment mechanisms. The material's natural elastic behavior replaces the need for multiple complex rigid alignment features.
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 effectively reduces positional variation between components, ensuring precise and repeatable alignment, improving the fit and finish of assemblies by averaging out manufacturing variances and facilitating easier assembly processes.
Implementation Method 1
a first plurality of elastically deformable alignment elements disposed on the first body panel... a second plurality of elastically deformable alignment elements... wherein the engagement of the alignment member and deformable member and first plurality of elastically deformable alignment elements and the second plurality of elastically deformable alignment elements elastically average a position of the second alignment portion relative to the first alignment portion
Data Source
AI summary
An elastically averaged alignment system includes a first alignment portion comprising an alignment member and a first plurality of elastically deformable alignment elements. The alignment system also includes a second alignment portion comprising an elastically deformable alignment member configured and disposed to be received by and deformably and matingly engaged with the alignment member and a second plurality of elastically deformable alignment elements configured and disposed to deformably and matingly engage the first plurality of deformable alignment elements, wherein the engagement of the alignment member and deformable member and first plurality of elastically deformable alignment elements and the second plurality of elastically deformable alignment elements elastically average a predetermined position of the second alignment portion relative to the first alignment portion.