Pedal-Operated Vehicle Door Adjuster for Ergonomic Tolerance Alignment

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Solution Overview

Problem

In vehicle manufacturing, manually adjusting door positions to meet tolerances is inconvenient, inaccurate, and can lead to technician injuries due to the need for awkward body movements.

Innovation Solution

A vehicle door adjuster apparatus with pedals that allow technicians to raise or lower doors using their legs, reducing manual strain and improving accuracy by using a bar connected to an actuator to align the door with the striker, facilitating precise adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a technician manually adjusts the door by pulling or pushing with arms and back muscles, then the door position can be changed to meet tolerances, but the technician experiences awkward stresses and potential injuries

Engineering Contradiction:

Improvedoor position toleranceVSAvoidtechnician ergonomics

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent replaces the manual mechanical system (technician using arm and back muscles) with a pedal-operated mechanical system. The pedal mechanism provides mechanical advantage, allowing the technician to use leg muscles instead of back and arm muscles, thereby resolving the contradiction between achieving precise door positioning and maintaining technician ergonomics.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a pedal-operated bar as an intermediary mechanism between the technician and the door. This intermediary provides mechanical advantage and transfers force from the technician's foot to the door, enabling precise position adjustment without direct manual handling, thus resolving the ergonomics issue while maintaining positioning accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If a technician manually adjusts the door by pulling or pushing, then the door position can be changed, but the adjustment may be inaccurate

Engineering Contradiction:

Improvedoor position toleranceVSAvoidadjustment accuracy

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The patent replaces imprecise manual pulling/pushing with a controlled pedal-operated mechanical system. The mechanical linkage and bar provide controlled, incremental movement of the door, improving adjustment accuracy while eliminating the variability associated with manual force application.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs a dynamic adjustment mechanism where the bar can be positioned at different locations along its length to engage with the door latch. This allows for fine-tuned, incremental adjustments to achieve precise door positioning, resolving the contradiction between manual adjustability and adjustment accuracy.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If the door is adjusted manually by deforming the attachment mechanism, then the tolerances can be satisfied, but the attachment mechanism may be damaged or compromised

Engineering Contradiction:

Improvedoor tolerance complianceVSAvoidattachment mechanism integrity

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent introduces a bar as an intermediary that engages with the door latch mechanism. This bar allows for controlled position adjustment without directly deforming the attachment mechanism. The bar transfers force through a controlled mechanical pathway, satisfying tolerances while preserving the integrity of the door's attachment mechanism.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent allows the bar to be preliminarily positioned at different locations along its length before engaging with the door latch. This preliminary positioning enables the technician to select the optimal engagement point that achieves the required door position without forcing or deforming the attachment mechanism, thus maintaining its integrity.

Inventive Principle:

Principle #10Preliminary action

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 apparatus enables efficient and accurate adjustment of vehicle doors to meet tolerances without straining technicians, reducing the risk of injury and improving ergonomics in manufacturing processes.

Implementation Method 1

An actuator can connect the frame to the bar. The actuator can be configured to enable the vehicle door to be manually raised or lowered by a predetermined distance

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Data Source

PatentUS9994271B2Apparatus for adjusting relative orientations of components, and methods of use and manufacture thereof

Publication Date: 2018.06.12 HONDA MOTOR CO LTD

AI summary

Some embodiments are directed to an adjuster for adjusting a position of a vehicle door relative to other vehicle components. The adjuster can include a pin that is configured to be held by a vehicle door latch so as to form a rigid connection between the pin and the vehicle door. The pin can also be configured to be released from the vehicle door latch upon actuation of a vehicle release mechanism. A frame can be supported by a surface that is static relative to the vehicle. An actuator can connect the frame to the pin. The actuator can be configured to enable the vehicle door to be manually raised or lowered by a predetermined distance that facilitates the vehicle door adopting a position that provides enhanced communication between the vehicle door latch and a vehicle striker.