Floating Connector Structure for 3D Assembly Misalignment
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Solution Overview
Problem
Existing floating connectors in automobiles are prone to assembly failures due to positional deviations between male and female fittings, requiring manual intervention and compromising automated assembly processes.
Innovation Solution
A floating connector with a simple structure, comprising a body part, attachment plate, and adjustable parts made of rubber and plastic, allowing for elastic deformation in three directions (XYZ) to accommodate positional deviations, facilitating automated assembly without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a floating connector is employed to accommodate positional deviations, then assembly robustness is improved, but the complexity of the connector structure increases
Solution Approach 1:
The patent employs a flexible membrane structure as the core component of the floating connector. The membrane can elastically deform in multiple directions to accommodate positional deviations between male and female fittings, providing the necessary flexibility without requiring complex mechanical adjustment mechanisms. This resolves the contradiction by achieving assembly robustness through material flexibility rather than structural complexity
Solution Approach 2:
The patent utilizes the elastic properties of the membrane material to enable dynamic parameter changes in the connector structure. The membrane's elasticity allows it to adapt its shape and position within a certain range, accommodating deviations in multiple directions while maintaining a simple overall structure. This approach improves reliability without proportionally increasing device complexity
2Ease of manufacture
If the floating connector structure is simplified, then manufacturing ease is improved, but the ability to accommodate positional deviations deteriorates
Solution Approach 1:
By using a flexible membrane instead of a complex mechanical structure, the patent achieves both simplicity in manufacturing and high adaptability. The membrane can be easily fabricated and integrated into the connector, while its elastic properties enable it to accommodate significant positional deviations in multiple directions, thus resolving this contradiction effectively
Solution Approach 2:
The patent employs composite material structures, combining the flexible membrane with rigid connector components. This composite approach allows the simple membrane structure to provide the necessary flexibility for accommodating deviations, while the rigid parts maintain structural integrity, achieving both ease of manufacture and high adaptability
3Manufacturing precision
If manual intervention is required for alignment, then connection precision is improved, but productivity deteriorates
Solution Approach 1:
The floating connector with its elastic membrane structure performs self-alignment automatically during the assembly process. The membrane's flexibility allows it to adapt to positional deviations without requiring manual intervention for alignment, thereby maintaining connection precision while enabling automated assembly and improving productivity
Solution Approach 2:
The patent introduces dynamic characteristics to the connector through the elastic membrane, which can automatically adjust its configuration in response to positional deviations. This dynamic adaptation eliminates the need for static, precision-critical alignment procedures that would require manual intervention, thus maintaining connection precision while enabling high-speed automated assembly
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 connector ensures precise alignment and connection of male and female fittings even with large positional deviations, reducing assembly failures and enhancing automated assembly efficiency by providing a controllable floating amount in three dimensions.
Implementation Method 1
the first adjustment part is capable of deforming elastically through the first foldable portion, so that the first adjustment part provides horizontal movement of the attachment plate relative to the body part
Implementation Method 2
the second adjustment part is capable of deforming elastically through the second foldable portion, so that the second adjustment part provides vertical movement of the attachment plate relative to the body part
Data Source
AI summary
A floating connector includes a body part, an attachment plate, a first adjustment part and a second adjustment part. The body part has an upper plate, a lower plate, and a sleeve disposed between the upper plate and the lower plate. The attachment plate has a connection hole therein and is jacketed outside the sleeve through the connection hole, and the first adjustment part is integrally connected to an inner wall of the connection hole of the attachment plate. The first adjustment part is capable of providing horizontal movement of the attachment plate relative to the body part. The second adjustment part is capable of providing vertical movement of the attachment plate relative to the body part.