Front-End Module Locking Mechanism for Motor Vehicle Chassis
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Solution Overview
Problem
The existing front-end assembly process for motor vehicles is time-consuming and complex due to the need to drill the fascia of the bumper beam for bolt tightening, which complicates the mounting of the front-end module onto the rail and requires aesthetically unpleasing cap plugs to cover the holes, making the operation slow and difficult.
Innovation Solution
A front-end assembly design featuring locking pins and fastening elements with a guiding slide mechanism that allows for rectilinear movement to lock the front-end module onto the railplate without drilling the fascia, using a tightening organ to move the fastening part relative to the railplate, and incorporating non-return cotter pins and complementary housings for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the fascia of the bumper beam is drilled to access mounting bolts, then the front-end module can be fastened to the rail, but the assembly process becomes time-consuming and requires aesthetic repairs with cap plugs
Solution Approach 1:
A fastening element is introduced as an intermediary component between the locking pin and the railplate. This fastening element includes a guiding slide that mediates the locking action, allowing the locking pin to engage with the railplate hole while providing guidance and constraint during the fastening process, thereby enabling access to mounting bolts without drilling the fascia
Solution Approach 2:
The fastening system is segmented into distinct functional components: the locking pin attached to the front-end module, the hole in the railplate, and the fastening element with the guiding slide. This segmentation allows each component to perform its specific function independently, with the guiding slide facilitating the locking action without requiring modification to the bumper beam fascia
2Ease of manufacture
If the fascia is drilled for bolt access, then mounting can proceed, but aesthetic integrity is compromised requiring cap plugs
Solution Approach 1:
The fastening element acts as an intermediary that enables bolt access through its own structure rather than through the fascia. The guiding slide and aperture mechanism provides the necessary access path for the locking pin while leaving the fascia intact, thus maintaining aesthetic integrity without compromising manufacturing ease
3Ease of operation
If mounting bolts are accessed from the front, then assembly can proceed, but the operation becomes complex and slow due to blind fastening
Solution Approach 1:
The guiding slide performs self-guiding functionality during the fastening operation. As the fastening element moves with the locking pin, the guiding slide automatically aligns itself with the hole in the railplate, providing self-service guidance without requiring external intervention or visual inspection, thereby simplifying the operation and reducing assembly time
Solution Approach 2:
The guiding slide is pre-positioned on the fastening element before the fastening operation begins. This preliminary positioning ensures that when the locking pin is inserted, the guiding slide is already in the correct orientation and position to guide the pin into the hole, eliminating the need for blind fastening and reducing operational complexity
Data Source
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AI summary
This front-end assembly (4) comprises a front-end module (16), at least one railplate (18A, 18B) adapted to be attached to a rail (14A, 14B) of a motor vehicle chassis, and means for fastening the railplate (18A, 18B) to the front-end module (16), the railplate (18A, 18B) comprising at least one hole for receiving a pin. The fastening means comprise, for the railplate (18A, 18B), at least one locking pin and at least one fastening element, said locking pin being attached to the front-end module (16) and being adapted to be received by said hole, said fastening element including a fastening part which is mechanically linked to said railplate (18A, 18B) and which is movable relative to the railplate (18A, 18B), said fastening part having at least one aperture for receiving said locking pin, and means for locking the front-end module (16) onto said railplate (18A, 18B), said locking means comprising at least one guiding slide, said guiding slide being contiguous with said aperture and being adapted to lock the locking pin, the locking being performed by a rectilinear movement of the fastening part from a first position in which the aperture is aligned with the hole, to a second position in which the guiding slide is aligned with the hole.