Lens Alignment Device for Motor Vehicle Lighting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing process for installing a lens on a motor vehicle lighting device housing is inefficient due to misalignment on a 3-2-1 reference point system, leading to dimensional deviations and frequent interventions, which result in high costs and potential collisions with internal components during the welding process.
Innovation Solution
A device comprising a receptacle device, a pre-centering device, and a holding device that allows for precise alignment of the lens relative to the housing without altering the position of the receptacle device, using fastening elements and movable frame elements to maintain accurate positioning and avoid collisions with internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the lens is aligned on the housing in a subsequent measurement process after welding, then dimensional deviations can be compensated, but the manufacturing process becomes complex and costly with frequent interventions required
Solution Approach 1:
The patent applies preliminary action by pre-aligning the housing on the receptacle device using a 3-2-1 reference point system before the welding process. This preliminary alignment ensures that the housing is correctly positioned relative to the lens mounting location, eliminating the need for subsequent complex measurement and realignment processes. The alignment is performed once at the beginning, maintaining simplicity throughout the manufacturing chain.
2Manufacturing precision
If the receptacle device position is changed to align the holding device, then lens positioning accuracy improves, but internal components may collide with the joining device
Solution Approach 1:
The patent segments the alignment and welding operations into distinct phases with fixed reference frames. The receptacle device holds the housing in a fixed position on the 3-2-1 reference point system, while the holding device is independently positioned above the lens. This segmentation allows each component to be aligned separately without causing collisions, as the receptacle device does not need to be moved during the welding process.
Solution Approach 2:
The patent introduces the 3-2-1 reference point system as an intermediary that mediates the alignment between the receptacle device, housing, and holding device. This reference system serves as a common coordinate framework that allows all components to be positioned accurately without requiring physical movement of the receptacle device, thereby preventing collisions with internal components.
3Measurement precision
If continuous manufacturing chain is broken for alignment measurement, then measurement accuracy improves, but productivity decreases
Solution Approach 1:
The patent performs the alignment measurement and positioning as a preliminary action before the welding process begins. The housing is aligned on the receptacle device using the 3-2-1 reference point system in advance, and this alignment is maintained throughout the subsequent welding operation. This eliminates the need to break the manufacturing chain for mid-process measurements, thereby maintaining continuous production and high productivity.
Data Source
AI summary
A method for joining a lens to a housing of a lighting device of a motor vehicle, in which the housing is accommodated and secured in a receptacle device. The method includes accommodating the lens in a pre-centering device, aligning the lens towards the housing during an alignment procedure and accommodating the lens by a holding device after the alignment procedure. The method further includes holding the lens by the holding device during a subsequent joining process, releasably attaching the holding device to the pre-centering device, aligning, via fastening elements, during the alignment procedure and moving the accommodated lens and the holding device attached to the pre-centering device relative to the receptacle device such that the lens and the holding device are aligned on the housing accommodated in the receptacle device.