Tolerance Compensation for Rigid Flat Cable Bolt Attachment
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Solution Overview
Problem
Rigid flat cables face challenges in being attached to bolts with production-related tolerances, as they cannot be bent or deformed to fit slightly larger or misaligned receiving holes, leading to installation issues, especially in automotive applications where production delays must be avoided.
Innovation Solution
A tolerance compensation system comprising a flat part with a recess for the bolt and a movable tolerance slider, allowing the bolt to be inserted even with deviations in position, with the recess dimensions larger than the bolt to accommodate tolerances, and the slider enabling alignment and secure fastening without deforming the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the recess in the flat part is made slightly larger than the bolt diameter to accommodate tolerances, then the bolt can be inserted even with positioning deviations, but the recess becomes too large to provide a precise fit and requires additional tolerance compensation mechanisms
Solution Approach 1:
The attachment system is segmented into three components: the flat part with a first recess, the tolerance slider with a second recess, and the bolt. The first recess has dimensions larger than the bolt to accommodate tolerances, while the second recess in the tolerance slider provides a precise fit. This segmentation allows each component to fulfill a specific function: the flat part provides tolerance accommodation, the tolerance slider provides precise positioning, and the bolt provides fastening.
Solution Approach 2:
The tolerance slider acts as an intermediary component between the flat part and the bolt. It receives the bolt through its second recess (which has precise dimensions matching the bolt) and transfers the connection to the flat part through its first recess (which has larger dimensions to accommodate tolerances). This intermediary structure resolves the contradiction by providing both tolerance accommodation and precise fit through different interfaces.
2Strength
If rigid flat cables are used for structural stability, then the cable maintains its shape and strength, but it cannot be bent or deformed to accommodate bolts with positional tolerances
Solution Approach 1:
The rigid flat cable is segmented by introducing the tolerance slider as a separate movable component. The flat part maintains its rigidity and structural strength, while the tolerance slider provides the necessary adaptability through its ability to move relative to the flat part. This segmentation allows the rigid cable structure to accommodate tolerance variations without requiring the cable itself to be flexible.
Solution Approach 2:
The tolerance slider is designed to be movable relative to the flat part, introducing dynamic adaptability into an otherwise rigid system. The slider can shift position to accommodate bolts with positional tolerances while the flat part and cable maintain their rigid structural integrity. This dynamic element resolves the contradiction between rigidity and adaptability.
3Ease of manufacture
If the recess dimensions are increased to accommodate bolts with maximum tolerance deviation, then the bolt can be inserted without deformation, but the recess becomes excessively large and compromises the precision of the connection
Solution Approach 1:
The connection precision is segmented between two interfaces: the interface between the bolt and the second recess (which provides precise fit) and the interface between the tolerance slider and the first recess (which accommodates tolerances). This segmentation allows the overall connection to be both easy to assemble and precisely positioned.
Solution Approach 2:
The tolerance slider serves as an intermediary that decouples the precision requirement from the tolerance accommodation requirement. The second recess in the tolerance slider maintains precise dimensions for accurate positioning, while the first recess has enlarged dimensions for easy assembly. The slider mediates between these two conflicting requirements.
Data Source
AI summary
The subject matter relates to a tolerance compensation comprising a flat part with a first recess for receiving a bolt of an attachment part and a tolerance slider with a second recess for receiving the bolt.