Radar Alignment System for Bumper Rail Tolerance
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Solution Overview
Problem
Radar apparatuses often experience misalignment due to assembly tolerances in vehicle components like bumper rails, front end modules, and vehicle bodies, leading to potential misalignment during mounting.
Innovation Solution
An alignment system comprising a fixing die, an angle measuring unit, and an alignment control unit that measures and corrects the mounting angle of the radar apparatus on the bumper rail before assembly, ensuring alignment within a normal range to prevent misalignment during vehicle assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the radar apparatus is mounted to the bumper rail after vehicle components are assembled, then the assembly process can be completed, but misalignment occurs due to assembly tolerances of the bumper rail, front end module, and vehicle body
Solution Approach 1:
The patent applies preliminary action by mounting and aligning the radar apparatus to the bumper rail before the bumper rail is assembled to the front end module and vehicle body. The alignment is performed on the bumper rail in isolation, allowing precise adjustment without the constraints of the complete vehicle assembly. This preliminary alignment prevents misalignment propagation through subsequent assembly steps.
Solution Approach 2:
The patent segments the alignment process from the overall vehicle assembly process. Instead of aligning the radar apparatus after complete assembly, the alignment is performed as a separate, preliminary step on the bumper rail component alone. This segmentation allows the alignment operation to be independent of assembly tolerances in other components.
2Strength
If the radar apparatus is mounted using welding or screw-coupling to the bumper rail, then the mounting is secure, but mounting tolerance cannot be satisfied due to wide tolerance ranges
Solution Approach 1:
The alignment is performed before the final mounting operation. The bumper rail is aligned with the radar apparatus while still in a workable state, and then secured through welding or screw-coupling. This preliminary alignment ensures that the mounting tolerance is satisfied before the strong mechanical connection is established.
Solution Approach 2:
The patent changes the state parameters of the bumper rail during the process. The bumper rail is held in a fixed, adjustable state during alignment, allowing precise positioning. After alignment is achieved within the required tolerance, the mounting state changes to a fixed, secure connection through welding or screw-coupling.
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 system effectively reduces the likelihood of radar apparatus misalignment caused by assembly tolerances, ensuring accurate alignment and reducing the need for subsequent corrections during vehicle assembly.
Implementation Method 1
an angle measuring unit for measuring a mounting angle of the radar apparatus mounted to the bumper rail
Data Source
AI summary
Disclosed are an alignment system and an alignment method for aligning a radar apparatus such that the alignment is not significantly influenced by tolerances in an assembly process of a bumper rail, a front end module, and a vehicle body.