Error-Proof Tube Connection With Anti-Crush Clip
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Solution Overview
Problem
In motor vehicle steering systems, there is a risk of unsuccessful tube connections due to premature installation of bolts, which can lead to misalignment and crushing of tubes during assembly, as assembly operators may mistakenly insert bolts before internal and external tubes are fully aligned.
Innovation Solution
An error-proofing clip with a tongue mechanism is mounted in the internal tube, blocking the bolt insertion until the tubes are fully aligned and providing visual and tactile feedback to prevent premature bolt installation, and an anti-crush feature to prevent tube crushing during proper connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bolt is installed before the internal tube is fully inserted into the external tube, then the assembly process can proceed faster, but the connection reliability deteriorates due to misalignment and potential crushing of the tubes
Solution Approach 1:
The error-proofing clip is installed in advance within the internal tube, with its tongue positioned to block the bolt hole. This preliminary action ensures that the bolt cannot be installed until the internal tube is fully inserted into the external tube, preventing misalignment and crushing while maintaining assembly efficiency
Solution Approach 2:
The error-proofing clip acts as an intermediary mechanism between the internal tube and the bolt. The tongue of the clip physically blocks the bolt hole, serving as a mediator that prevents premature bolt installation and ensures proper tube alignment before connection
2Strength
If the nut is tightened to securely pinch the tubes together, then the connection strength is improved, but the tubes may be crushed due to excessive tightening force
Solution Approach 1:
The U-shaped anti-crush clip is installed beforehand inside the internal tube, positioned to protect the tube walls from crushing forces. This preliminary protective measure allows the nut to be tightened to the required strength without causing damage to the tubes
Solution Approach 2:
The anti-crush clip serves as an intermediary protective element between the tightening force applied by the nut and the tube walls. It distributes and cushions the compressive forces, preventing localized crushing while maintaining secure connection
Data Source
AI summary
An internal tube is inserted into an external tube to align first bolt holes provided through opposed walls of the external tube with second bolt holes provided through opposed walls of the internal tube. A bolt is inserted through the first bolt holes and through the second bolt holes to connect the tubes together when the bolt holes are aligned. An error-proofing clip is mounted in the internal tube and has a tongue extending from the end thereof to reach into the external tube and block the insertion of the bolt through the first bolt holes of the external tube until the insertion of the internal tube has proceeded fully to bring the first bolt holes of the external tube and the second bolt holes of the internal tube into alignment with one another, thereby preventing a premature installation of the bolt through only the first bolt holes.