Floating Bracket Presenter for Tolerance-Accurate Ultrasonic Welding
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Solution Overview
Problem
Existing bracket presenters for ultrasonic welding of sensor brackets to vehicle bumper fascias are complex and costly due to the need for numerous machined and assembled parts, and they do not adequately accommodate tolerance variations between the parts.
Innovation Solution
A one-piece bracket presenter with integrally formed first and second bracket portions featuring tapered features and springs that allow for floating and positive location, enabling efficient assembly and ultrasonic welding of sensor brackets to vehicle bumper fascias.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional multi-part bracket presenters are used, then tolerance variations between parts can be accommodated, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate bracket presenter components into a single integrated fixture structure. The fixture includes a base plate with integrated positioning features, clamping mechanisms, and alignment features all as one piece, eliminating the need for multiple separate parts while maintaining the ability to accommodate tolerance variations through built-in adjustment capabilities.
Solution Approach 2:
The fixture incorporates adjustable parameters such as movable clamping elements, adjustable positioning blocks, and flexible mounting features that can adapt to different tolerance conditions. These parameter changes allow the single-part fixture to accommodate tolerance variations without requiring multiple discrete components.
2Adaptability or versatility
If traditional multi-part bracket presenters are used, then tolerance variations can be accommodated, but manufacturing cost increases
Solution Approach 1:
By merging multiple parts into a single integrated fixture, the patent reduces manufacturing cost through economies of scale, simplified production processes, and reduced assembly requirements. The single-part design can be manufactured more efficiently while still incorporating features for tolerance accommodation.
Solution Approach 2:
The fixture is designed to be self-adjusting and self-aligning, reducing the need for complex assembly procedures and specialized manufacturing processes. The integrated design includes built-in features that automatically compensate for tolerance variations, eliminating the need for costly precision assembly of multiple parts.
3Ease of manufacture
If a one-piece bracket presenter design is used, then manufacturing complexity and cost are reduced, but alignment precision may be compromised
Solution Approach 1:
The one-piece fixture incorporates localized precision features at critical alignment points, such as precision-machined locating surfaces, tapered positioning pins, and keyed features. These local quality enhancements ensure accurate alignment and positioning despite the overall simplicity of the single-part design.
Solution Approach 2:
The fixture includes pre-built alignment features and pre-positioned mounting locations that ensure precise alignment from the outset. The one-piece design incorporates preliminary alignment actions during the manufacturing process itself, such as precision casting or machining of locating surfaces, to eliminate the need for complex post-assembly alignment procedures.
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 one-piece design reduces manufacturing complexity and cost while allowing for precise alignment and accommodation of tolerance variations, facilitating automated loading and secure welding of sensor brackets.
Implementation Method 1
A spring, such as a compression spring, is circumscribed about the post and configured to engage between the first and second bracket portions when the bracket portions are in the extended position. The spring provides a pre-load between the first and second bracket portions.
Data Source
Figure 1A~1B
Figure 2
Figure 3A
AI summary
A bracket presenter (54) for an ultrasonic welder (10) includes a one-piece first bracket portion (56) and a one-piece second bracket portion (58) mounted relative to one another. First and second tapered features are respectively provided by the first and second bracket portions (56, 58) and are nested relative to one another. The first and second tapered features engage in an extended position and are spaced from one another in a compressed position to provide a clearance (84) enabling the first and second bracket portions (56, 58) to float lateral relative to one another. A spring biases (64) the first and second bracket portions (56, 58) apart.