Elastically Deformable Alignment Member for Precision Assembly
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Solution Overview
Problem
Matable components often experience significant positional variation due to manufacturing variances, leading to misalignment, noise, and poor assembly quality, particularly in vehicular components with oversized holes and undersized bosses.
Innovation Solution
An elastically averaged alignment system using deformable alignment members with tabs that elastically deform to align components precisely, minimizing manufacturing positional variance and providing a stable, noise-reducing interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If oversized holes and undersized bosses are used for alignment, then manufacturing tolerance is accommodated, but alignment precision deteriorates
Solution Approach 1:
The alignment member is made elastically deformable, changing its physical state from rigid to flexible. This allows it to adapt to manufacturing variances through elastic deformation while maintaining precise alignment, resolving the contradiction between tolerance accommodation and alignment precision
Solution Approach 2:
The alignment member transitions from a static rigid structure to a dynamic elastically deformable structure. This enables the alignment member to adjust its position and shape in response to manufacturing tolerances, achieving both adaptability and precision simultaneously
2Ease of operation
If clearance is provided between alignment features, then assembly ease is improved, but relative motion and noise increase
Solution Approach 1:
The elastically deformable alignment member changes its physical parameters during assembly, allowing initial clearance for easy assembly, then deforming to eliminate clearance and prevent noise, thus resolving the contradiction between assembly ease and noise reduction
Solution Approach 2:
The elastic material provides a cushioning effect that absorbs assembly shocks and variations, allowing easy assembly while preventing harmful relative motion and noise during operation
3Strength
If rigid alignment features are used, then structural strength is maintained, but positional variation increases
Solution Approach 1:
The alignment member transitions from rigid to elastically deformable, allowing it to maintain structural integrity while adapting to positional variations through controlled elastic deformation, thus resolving the contradiction between strength and positional precision
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 ensures precise alignment and stable coupling of components, reducing relative motion and noise, while allowing for repeatable assembly and disassembly, thereby enhancing the quality and functionality of the assembly.
Implementation Method 1
the alignment member is an elastically deformable material such that when the alignment member is inserted into another alignment aperture of another component, the alignment member elastically deforms to an elastically averaged configuration
Data Source
AI summary
In one aspect, a component for an elastically averaged alignment system is provided. The component includes a body, an inner wall formed in the body and defining an alignment aperture, and an alignment member. The alignment member includes a pair of tabs extending from the body, and the alignment member is an elastically deformable material such that when the alignment member is inserted into another alignment aperture of another component, the alignment member elastically deforms to an elastically averaged configuration to facilitate aligning the component relative to the another component of the elastically averaged alignment system. The alignment aperture is configured to receive another alignment member of another component of the elastically averaged alignment system.