Self-Centering Console Connectors for Automated Vehicle Assembly
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Solution Overview
Problem
The automation of center console installation in vehicle manufacturing is limited due to the need for precise positioning and human intervention, as existing methods require elaborate control mechanisms and precise handling to ensure accurate engagement of connectors with the vehicle floor.
Innovation Solution
A console element with self-centering front and rear connectors that can be inserted into receptacles on the vehicle floor, allowing for horizontal movement and alignment, enabling precise positioning without complex control mechanisms, and facilitating fully automated installation by robots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional connector engagement methods are used, then connectors can be engaged with the vehicle floor, but precise positioning and human intervention are required, limiting automation
Solution Approach 1:
The connector is designed with self-centering capability through its geometric shape, allowing it to automatically align and engage with the receptacle without external positioning assistance. The connector's cross-section features a trapezoidal profile that guides it into proper alignment during insertion, enabling fully automated installation without human intervention for positioning
Solution Approach 2:
The connector's cross-sectional geometry is changed to a trapezoidal shape with specific angle relationships. The first angle (α) and second angle (β) are designed such that α + β < 180°, creating a self-centering effect that automatically positions the connector correctly as it engages with the receptacle, eliminating the need for precise pre-positioning
2Manufacturing precision
If precise positioning mechanisms are implemented, then accurate engagement is achieved, but device complexity increases
Solution Approach 1:
The self-centering connector design eliminates the need for complex control mechanisms, sensors, and actuators by incorporating the positioning function directly into the connector's geometric shape. The trapezoidal cross-section with specific angle relationships automatically guides the connector into correct alignment during insertion
Solution Approach 2:
The positioning function is extracted from the control system and embedded into the connector's geometry itself. This removes the need for separate positioning mechanisms, sensors, and control electronics, significantly simplifying the overall system
3Manufacturing precision
If human workers perform positioning, then accurate placement is achieved, but productivity is reduced
Solution Approach 1:
The self-centering connector automatically positions itself during insertion, allowing robots to perform installation at high speeds without the need for slow, precise manual positioning. The geometric self-alignment mechanism works instantly during the insertion motion, enabling rapid automated assembly
Solution Approach 2:
The manual positioning operation is replaced by a purely mechanical self-centering mechanism built into the connector geometry. This mechanical feature provides automatic alignment during insertion, replacing the need for human workers to manually position and align the connector
Data Source
AI summary
A console element for connection to a vehicle floor of a vehicle, having a main body having a main body base and main body side walls, and having front connectors and rear connectors that are attached in each case to an underside of the main body base and can be inserted in receptacles arranged on the vehicle floor of the vehicle by means of a horizontal movement of the main body along a joining direction, characterized in that the front connectors and the rear connectors are designed to be self-centering.