Positioning Device for Vehicle Assembly Alignment
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Solution Overview
Problem
Current assembly methods for vehicle components, particularly those involving different materials like plastic and sheet metal, require additional process steps and complexity due to the use of jigs or templates, which slow down the assembly process and complicate the alignment of parts with varying thermal expansion coefficients.
Innovation Solution
A positioning device with a contact area that can absorb forces and maintain a predetermined distance between carrier and reference parts, featuring a base area connected via web elements and a hinge joint, allowing for simple alignment and fixation without the need for temporary gauges or templates, and a method that involves severing web elements to facilitate the positioning and fixing of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If jigs or templates are used to align components, then alignment accuracy is improved, but the assembly process time increases and process complexity increases
Solution Approach 1:
The positioning device is pre-integrated onto the carrier part before assembly, with contact areas and web elements already in place. This preliminary configuration eliminates the need for separate alignment operations during assembly, as the device automatically provides positioning when the carrier part is mounted on the reference part.
Solution Approach 2:
The positioning device merges multiple functions into a single integrated structure: the base area attaches to the carrier part, web elements provide structural connection, and contact areas perform the alignment function. This consolidation eliminates the need for separate jigs or templates, reducing both process time and complexity while maintaining alignment accuracy.
2Manufacturing precision
If jigs or templates are used to align components, then alignment accuracy is improved, but the process complexity increases
Solution Approach 1:
The positioning device is segmented into distinct functional elements: a base area for attachment to the carrier part, web elements for structural connection, and contact areas for alignment with the reference part. This segmentation allows each element to perform its specific function efficiently, simplifying the overall assembly process compared to using complex external jigs or templates.
Solution Approach 2:
The positioning device is self-contained and self-positioning. Once the carrier part is mounted on the reference part, the integrated positioning device automatically assumes the correct position and orientation through its contact areas, eliminating the need for operators to manually position or adjust external alignment tools.
3Strength
If web elements are used to connect contact area to base area, then force absorption capability is improved, but device complexity increases
Solution Approach 1:
The web elements are designed as thin, flexible connecting structures that can absorb forces acting between the contact area and base area. These web elements provide sufficient strength and flexibility to maintain the positioning function while accommodating thermal expansion and contraction forces, without requiring complex structural support systems.
4Reliability
If a hinge joint is used to connect contact area to base area, then reliability is improved, but device complexity increases
Solution Approach 1:
The hinge joint allows the contact area to rotate or pivot relative to the base area, changing its orientation parameter to accommodate variations in assembly position and thermal expansion. This passive adaptation through parameter change ensures reliable contact and positioning without requiring complex active control mechanisms or multiple adjustment components.
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
This solution reduces the number of assembly process steps, ensures accurate alignment, and maintains a consistent joint gap, enhancing the quality and efficiency of vehicle component assembly by eliminating the need for temporary gauges and simplifying the alignment process.
Implementation Method 1
the contact area has a first end section which is connected to a base area via at least one web element... forces acting on the positioning device can be introduced via the contact area through the web elements into the base area
Implementation Method 2
the joint can be a hinge joint, in particular a film hinge joint... the contact area is connected to the base area via the hinge joint and therefore cannot fall off in an uncontrolled manner
Data Source
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AI summary
The invention relates to a positioning device (10), for the orientation of a carrier part (1) in relation to a reference part (2) in a predefined position, having a contact region (12), by way of which the positioning device (10) can be brought into connection with the reference part (2), and a method for producing an arrangement according to the invention.