Seat Height Adjustment Assembly for Zero-Clearance Gear Meshing
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Solution Overview
Problem
Current methods for assembling height adjustment systems for seats face challenges in eliminating clearance between the pinion and toothed sector, leading to suboptimal contact during crashes and noise issues, while requiring additional parts or being costly due to tolerance stack-up control.
Innovation Solution
A method involving a tooling system with complementary recesses and members to align and secure the output member, connecting rod, and drive module, using permanent fastening means like welding to eliminate clearance and ensure precise fitment between the pinion and toothed sector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembly methods are used to assemble the height adjustment system, then the assembly process is simpler, but clearance remains between the pinion and toothed sector leading to suboptimal crash resistance and noise issues
Solution Approach 1:
The patent applies preliminary action by pre-aligning the output member along the transverse axis using tooling before the permanent fastening operation. This preliminary positioning ensures that when the housing and drive module are permanently fastened to the flange, the pinion and toothed sector are already in optimal contact without clearance, thereby improving crash resistance without requiring complex adjustment mechanisms during the actual assembly.
2Reliability
If tolerance stack-up control is used to eliminate clearance, then crash resistance improves, but manufacturing costs increase
Solution Approach 1:
The patent introduces tooling as an intermediary device during assembly that temporarily holds the output member in the correct aligned position. This mediator allows the pinion and toothed sector to be positioned with precise contact without requiring tight manufacturing tolerances on the permanent components themselves, thereby achieving improved crash resistance while avoiding the high costs associated with tight tolerance stack-up control.
3Stability of the object's composition
If permanent fastening means are used to secure the housing and drive module, then assembly stability improves, but repairability decreases
Solution Approach 1:
The patent merges the housing and drive module assembly onto the flange using permanent fastening means such as welding or adhesive bonding. This combining creates a stable, integrated assembly that eliminates relative movement and ensures optimal contact between the pinion and toothed sector. The trade-off of reduced repairability is accepted in exchange for the improved stability and reliability of the height adjustment system during vehicle operation and crash events.
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 method effectively eliminates clearance between the pinion and toothed sector, enhancing crash resistance and reducing noise, without the need for additional parts and minimizing costs by ensuring a precise, permanent fit during assembly.
Implementation Method 1
securing, in particular by at least one permanent fastening means such as a weld (70) or an adhesive, the first housing (30), the flange (11) and the drive module (20)
Data Source
AI summary
A method for assembling a height adjustment system for a seat comprising a seat frame comprising at least one a flange extending a longitudinal direction and comprising, in a transverse direction, an inner side and an outer side, a first housing arranged on the first side of the flange in the transverse direction, and a drive module comprising an adjustment mechanism, the adjustment mechanism being arranged on a second side of the flange in the transverse direction, opposite the first side, coincident with the other of the inner side or the outer side, wherein the first housing, the flange and the drive module are secured together by at least one permanent fastening means, such as a weld or such as adhesive.