Seat Frame Collar Tolerance Split for Faster Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing vehicle seat frame collars require multiple time-consuming steps, leading to high production costs due to stringent dimensional accuracy requirements for both the outer and inner diameters of the cylindrical portions.
Innovation Solution
A method that sets a smaller dimensional tolerance for the sliding contact portion than the insertion-receiving portion, allowing for a more efficient production process with fewer steps, where the collar member has a cylindrical portion and a flange, with the sliding contact portion between the flange and the center, and the insertion-receiving portion between the center and the opposite end, facilitating cost reduction by loosening control over the outer peripheral portion's tolerance beyond the sliding contact region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple deep drawing processes are sequentially performed to reduce the diameter of the cylindrical portion gradually, then high dimensional accuracy of both outer and inner diameters is achieved, but the number of production steps increases and production time increases
Solution Approach 1:
The invention applies different dimensional tolerances to different portions of the collar member. The sliding contact portion (outer peripheral surface) is given a first dimensional tolerance, while the inner peripheral surface is given a second dimensional tolerance that is larger than the first. This local differentiation allows the inner diameter to be produced with fewer processing steps while maintaining sufficient functionality, thereby resolving the contradiction between manufacturing precision and productivity.
2Manufacturing precision
If stringent dimensional accuracy is applied to both outer and inner diameters of the cylindrical portion, then high quality collar members are produced, but production cost increases
Solution Approach 1:
The invention differentiates the dimensional requirements for different functional areas of the collar member. The sliding contact portion requires tighter tolerance (first dimensional tolerance) for proper operation with the side frame, while the inner peripheral surface that receives the pipe member can accommodate larger tolerance (second dimensional tolerance). This local quality approach reduces manufacturing cost by eliminating the need to apply stringent tolerances uniformly across the entire component.
3Reliability
If the same dimensional tolerance is applied to both sliding contact portion and insertion-receiving portion, then uniform manufacturing standards are maintained, but production time and cost increase unnecessarily
Solution Approach 1:
The invention recognizes that different portions of the collar member have different functional requirements and applies corresponding dimensional tolerances. The sliding contact portion (outer peripheral surface) is given a first dimensional tolerance to ensure proper sliding contact with the side frame, while the insertion-receiving portion (inner peripheral surface) is given a larger second dimensional tolerance. This differentiated approach maintains functional reliability while reducing production time by eliminating unnecessary precision requirements in non-critical areas.
Data Source
AI summary
A vehicle seat frame includes a pair of side frames constituting side portions of a seat cushion frame, and a pipe member rotatably fitted at respective end portions in sliding holes of the side frames, thereby coupling the side frames to each other. At least one of the end portions of the pipe member is coupled to the corresponding side frame via a collar member having a cylindrical shape. An outer peripheral portion of the collar member has a sliding contact portion in sliding contact with a peripheral surface of the sliding hole. An inner peripheral portion of the collar member has an insertion-receiving portion into which the corresponding end portion of the pipe member is inserted and to which the corresponding end portion of the pipe member is secured. The dimensional tolerance of the sliding contact portion is set smaller than the dimensional tolerance of the insertion-receiving portion.