Nested Tolerance Compensation Assembly for Compact High-Load Joints
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Solution Overview
Problem
Existing tolerance compensation devices in vehicle construction are limited by their size and load-bearing capacity, often requiring a shortened compensation path to achieve a compact design, which can compromise their effectiveness.
Innovation Solution
A nested design for the base element and compensating element with multiple coupling interfaces allows for a smaller, more compact device without shortening the compensation path, utilizing threaded engagements and plastic materials for enhanced strength and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the device is designed to be compact and smaller, then the device size is reduced, but the compensation travel needs to be shortened which compromises effectiveness
Solution Approach 1:
The base element and compensating element are arranged in a nested configuration where the compensating element is positioned within the base element's structure. This nesting allows the device to achieve a compact overall volume while maintaining the full compensation travel distance through the axial movement of the compensating element relative to the base element.
2Volume of moving object
If the device is designed to be compact and smaller, then the device size is reduced, but the load-bearing capacity is reduced
Solution Approach 1:
The device utilizes composite construction with the base element and compensating element made from plastic materials. This composite approach allows the device to maintain high load-bearing capacity despite the reduced size, as the plastic materials provide sufficient strength while enabling a more compact overall design.
Solution Approach 2:
The nested arrangement of the base element and compensating element optimizes the distribution of mechanical loads through multiple coupling interfaces. This nested structure allows the load-bearing capacity to be maintained or even increased despite the reduced device volume, as the forces are distributed across the nested components and their coupling interfaces.
3Strength
If metal materials are used, then the load-bearing capacity is high, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention replaces traditional metal materials with plastic materials for the base element and compensating element. This material substitution maintains sufficient load-bearing capacity while dramatically simplifying the manufacturing process and reducing production costs. The plastic components can be manufactured using injection molding or similar processes, eliminating the need for complex metalworking operations.
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 solution enables a compact, high-strength tolerance compensation device with increased load-bearing capacity, allowing for effective tolerance compensation without sacrificing design compactness, and offers cost savings and simplified manufacturing.
Implementation Method 1
a screw element for screwing the components together, e.g. a screw or a threaded bolt, is guided through correspondingly provided openings in the components and through the tolerance compensation device. When the screw element is screwed together, the compensation element is rotated relative to the base element by a drive spring connected between the screw element and the compensation element
Data Source
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AI summary
The invention relates to a device (10.x) for compensating tolerances between two components (B1, B2) to be joined together, comprising at least: - a base element (20) and - a compensating element (30) threaded in engagement with the base element (20), which can be moved from a starting position (P1) by rotating it relative to the base element (20), - a radially flexible drive element (50) acting in a predetermined direction (R), and - a holding device (70, 700) for connection to one of the components (B1, B2), wherein the holding device (70, 700) is designed as an integrated part of the base element (20) or the compensating element (30) or as a separate part and can be detachably arranged on one of the components (B1, B2) in a form-fitting and/or force-fitting manner, and - wherein the base element (20) and the compensating element (30) are interlocked in this waythat at least two coupling interfaces (61 to 63) are formed between the basic element (20) and the compensating element (30).