Radar Mounting Device with Resilient Grommet and Ball Stud
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Solution Overview
Problem
Existing vehicle Forward Looking Radars (FLRs) require cumbersome and costly installation processes, with large brackets and multiple attachment points, leading to increased manufacturing cycle times due to variations in vehicle height and stance, and a need for accurate alignment within narrow tolerances while minimizing weight and cost.
Innovation Solution
A radar mounting device utilizing resilient grommets and ball studs with adjustable nuts for secure attachment to the vehicle bumper, allowing for snap-fit engagement and adjustable alignment to ensure accurate positioning of the radar module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large brackets with multiple attachment points are used to attach FLR, then the FLR can be securely attached to the vehicle, but the device complexity and weight increase
Solution Approach 1:
The mounting device is divided into separate functional components: a bracket assembly with attachment points, a separate alignment mechanism with adjustment features, and a securing system. This segmentation allows each component to be optimized independently, reducing overall complexity while maintaining secure attachment capability.
Solution Approach 2:
The alignment and adjustment functions are extracted as separate adjustable features from the main bracket structure. This allows the bracket itself to remain simple while providing precise positioning through dedicated alignment mechanisms that can be adjusted independently.
2Manufacturing precision
If adjustment of FLR is performed offsite at supplier facility, then alignment accuracy can be achieved, but manufacturing cycle time increases
Solution Approach 1:
The bracket and alignment mechanisms are pre-assembled and pre-calibrated at the supplier facility before delivery to the assembly plant. This preliminary preparation ensures that the components are ready for quick installation and adjustment on the assembly line, reducing manufacturing cycle time while maintaining alignment accuracy through pre-established reference features.
Solution Approach 2:
The alignment mechanism includes self-adjusting features that allow workers at the assembly line to make precise adjustments without requiring specialized equipment or extensive training. The design incorporates self-aligning geometric features that guide proper positioning, enabling quick on-site adjustment while maintaining high alignment accuracy.
3Measurement precision
If FLR attachment is designed for precise alignment within narrow tolerances, then measurement accuracy is improved, but ease of manufacture decreases
Solution Approach 1:
The design incorporates adjustable parameters in the alignment mechanism that allow workers to fine-tune the FLR position within narrow tolerances. By providing adjustable mounting points and alignment features with controlled degrees of freedom, the system achieves precise alignment while maintaining ease of manufacture through simple adjustment procedures rather than complex precision machining requirements.
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
Facilitates efficient and cost-effective installation of FLRs with reduced manufacturing time and weight, enabling precise alignment and secure attachment within narrow tolerances, suitable for integration on a moving assembly line.
Implementation Method 1
a resilient grommet secured within an opening formed in the component. The device may also have a stud for attachment to the vehicle body. The stud may have a ball portion received within the resilient grommet for attaching the component to the stud.
Data Source
AI summary
An exemplary radar mounting device for attaching a component to a vehicle body may include a resilient grommet secured within an opening formed in the component. The device may also have a stud for attachment to the vehicle body. The stud may have a ball portion received within the resilient grommet for attaching the component to the stud. In addition, the device may have a nut fastened to the stud to secure the component to the stud.