Elastically Averaging Self-Retaining Alignment System

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Solution Overview

Problem

Current alignment systems for mating components, such as those in automotive vehicles, face significant positional variations due to manufacturing variances, leading to misalignments and reduced assembly quality, and often require separate fasteners for alignment and securement, which can result in loose connections over time.

Innovation Solution

An elastically averaging self-retaining alignment system featuring a first component with a hollow tube alignment element and a second component with an aperture having inwardly extending tabs, allowing the alignment element to deform and securely engage the aperture in multiple directions, eliminating the need for additional fasteners.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate alignment features and fastener components are used, then alignment and securement functions are provided, but the effectiveness of each is limited and additional components are required

Engineering Contradiction:

Improvealignment and securement functionalityVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines alignment and securement functions into a single integrated alignment feature. The alignment feature includes a boss with an aperture that serves both to align components during assembly and to retain the fastener component, eliminating the need for separate alignment pins and fasteners.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The alignment feature is designed to perform multiple functions: it provides alignment during assembly, serves as a guide for fastener insertion, and acts as a retention structure for the fastener component. This multi-functional design reduces the total number of parts required in the assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If heat staking is employed to fasten components, then components are secured together, but clearance to the metal component prevents tight holding and produces loosened assembly over time

Engineering Contradiction:

Improveconnection stabilityVSAvoidheat stake tool design

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of designing the heat stake tool with clearance to avoid damage (conventional approach), the patent inverts the approach by using a integrated alignment feature that inherently provides tight holding without requiring clearance. The boss and aperture configuration ensures the fastener is held tightly against the metal component.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The alignment feature with boss and aperture configuration provides self-aligning and self-retaining properties. The inwardly extending tabs and aperture geometry automatically guide and secure the fastener component without requiring additional clearance or complex tooling design.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If alignment features are oversized to provide spacing for free movement, then components can align without interference, but significant positional variation occurs between mated components

Engineering Contradiction:

Improvealignment processVSAvoidalignment precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent optimizes the dimensional parameters of the alignment feature, specifically the ratio between the boss diameter and aperture diameter. By controlling these parameters within specific ranges, the design achieves both ease of assembly and high alignment precision, eliminating the need for oversized features that cause positional variation.

Inventive Principle:

Principle #35Parameter changes

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 provides precise two-way or four-way alignment and retention of components, minimizing manufacturing positional variance and enhancing assembly quality by maintaining a secure, vibration-resistant connection without additional fasteners.

Implementation Method 1

an elastically deformable alignment element fixedly disposed with respect to the first alignment member, the alignment element having a hollow tube... Portions of the elastically deformable alignment element when inserted into the alignment feature elastically deform to an elastically averaged final configuration

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9447806B2Self-retaining alignment system for providing precise alignment and retention of components

Publication Date: 2016.09.20 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

An elastically averaging self-retaining alignment system includes a first component and a second component. The first component includes a first alignment member and an elastically deformable alignment element fixedly disposed with respect to the first alignment member, the alignment element having a hollow tube. The second component includes a second alignment member and an alignment feature fixedly disposed with respect to the second alignment member, the alignment feature having an aperture with a plurality of inwardly extending tabs. The elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage the alignment feature. Portions of the elastically deformable alignment element when inserted into the alignment feature elastically deform to an elastically averaged final configuration that aligns and retains the first component relative to the second component in at least two of four planar orthogonal directions.