Vehicle Frame Compensator Assembly for Spacing Variance
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Solution Overview
Problem
Vehicle frame assembly is hindered by production variances leading to inconsistent spacings and dimensions, requiring additional components like spacers or bent brackets to maintain structural integrity while using lighter materials.
Innovation Solution
A compensator assembly with a base member and extension member, where a fastener is used to threadably couple with the base and extension members, allowing the extension member to rotate and contact the second frame component, thereby securing the gap between frame components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If weld spacers or bent connection brackets are used to accommodate production variance, then manufacturing precision is improved, but device complexity and weight increase
Solution Approach 1:
The extension member is designed to be rotatable relative to the base member, allowing dynamic adjustment of the compensator assembly length to accommodate production variances in frame component spacing. This rotational capability enables the assembly to adapt to different spacing requirements without requiring multiple fixed-length components or complex welding operations.
Solution Approach 2:
The compensator assembly changes its effective length parameter by rotating the extension member between retracted and extended positions. This parameter change allows the same assembly to accommodate a range of spacing variations, eliminating the need for multiple specialized components and reducing overall assembly complexity.
2Manufacturing precision
If weld spacers or bent connection brackets are used to accommodate production variance, then manufacturing precision is improved, but weight increases
Solution Approach 1:
The rotatable extension member allows the compensator assembly to achieve the necessary reach and positioning capability dynamically rather than requiring a permanently extended structure. This reduces the amount of material needed while maintaining the ability to accommodate spacing variances.
Solution Approach 2:
The compensator assembly is divided into a base member and a separate extension member that can be independently sized. This segmentation allows the extension member to provide the necessary reach only when needed, reducing overall material usage and weight compared to a single oversized component.
3Adaptability or versatility
If the extension member is made longer to accommodate larger gaps, then adaptability is improved, but device complexity and weight increase
Solution Approach 1:
Rather than creating multiple fixed-length extension members for different gap sizes, the invention uses a single extension member with rotational capability. This dynamic mechanism provides continuous adaptability across a range of gap sizes without requiring multiple discrete components or complex selection systems.
Solution Approach 2:
The extension member serves multiple functions: it can be rotated to different angles, extended to different effective lengths, and positioned at various orientations. This multi-functionality allows a single component design to accommodate a wide range of gap conditions without requiring specialized variants.
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 compensator assembly effectively accommodates manufacturing inconsistencies by providing a secure and rigid connection between frame components, maintaining structural integrity while allowing the use of lighter materials.
Implementation Method 1
An extension member is threadably coupled with the base member. Rotation of the fastener unthreads the extension member until it contacts the second frame component.
Data Source
AI summary
A compensator assembly for a vehicle frame includes a base member having a clip engaging a first frame component spaced from a second frame component. An extension member is threadably coupled with the base member. A fastener extends coaxially through the base and the extension members to engage the first and second frame components. Rotation of the fastener unthreads the extension member until it contacts the second frame component.