Movable Headlamp Support for Tolerance Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing front-end modules for vehicles face challenges in assembling headlight carriers on energy absorption elements due to manufacturing tolerances, requiring additional tolerance compensation and potentially weakening the energy absorption element, which can deteriorate its crash behavior.
Innovation Solution
A support element is guided within a receiving structure on the energy absorption element, allowing for linear movement during assembly to compensate for tolerances without additional mechanical work or weakening the element, and remains movable post-assembly to prevent stress and enhance crash behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the headlight carrier is rigidly fastened to the energy absorption element, then assembly precision is improved, but the energy absorption element is weakened and crash behavior deteriorates
Solution Approach 1:
The support element is designed to be movable within the receiving structure during assembly, allowing dynamic adjustment to compensate for manufacturing tolerances. After assembly, the support element remains movable to allow the energy absorption element to deform freely during impact, preventing rigid constraints that would weaken crash behavior.
Solution Approach 2:
The support element acts as an intermediary between the headlight carrier and the energy absorption element. It provides a form-fitting connection that enables tolerance compensation without requiring additional tolerance compensation elements, while maintaining the structural integrity and energy absorption capability of the energy absorption element.
2Ease of operation
If the headlight carrier is positioned far from the assembly support, then ease of assembly is improved, but stability deteriorates due to unfavorable leverage and vibrations
Solution Approach 1:
The mounting system is segmented into multiple functional components: the assembly support, the energy absorption element with receiving structure, and the movable support element. This segmentation allows the headlight carrier to be positioned optimally for assembly while the support element provides stability and vibration resistance through its form-fitting connection.
3Manufacturing precision
If additional tolerance compensation elements are added, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The support element serves multiple functions simultaneously: it provides a form-fitting connection to the headlight carrier, enables tolerance compensation through its movability within the receiving structure, and maintains the energy absorption capability of the energy absorption element. This multi-functionality eliminates the need for separate additional tolerance compensation elements, reducing device complexity.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Front end module comprises a headlamp support (30) arranged on an energy absorbing element (21) via a support element (40). The energy absorbing element has a holding structure (22) in which is guided the support element. Preferred Features: The headlamp support is movably fixed to the energy absorbing element in one direction. The connected between the support element and the energy absorbing element has no holes.