Slip Plane Bracket for Headlamp Module Adjustment
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Solution Overview
Problem
Vehicle assembly and repair are hindered by tolerance stack-up issues, leading to unsatisfactory fit and finish in vehicle front ends due to variations in part sizes and shapes, particularly when assembling and repairing headlamp modules.
Innovation Solution
A slip plane bracket system that allows adjustable attachment of headlamp modules to a vehicle's front end bolster, enabling X and Y directional adjustments to compensate for tolerance variations, featuring a body portion, ramp, retainer flange, and anti-rotation flange for precise alignment and secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional rigid attachment methods are used to assemble headlamp modules to the front end, then assembly speed is improved, but fit and finish quality deteriorates due to tolerance stack-up
Solution Approach 1:
The bracket incorporates adjustable features that allow dynamic repositioning of the headlamp module in X (longitudinal) and Y (lateral) directions after initial assembly, enabling operators to compensate for tolerance variations and achieve proper fit and finish without requiring perfect manufacturing tolerances
Solution Approach 2:
The bracket design includes adjustable parameters such as repositionable mounting points and flexible attachment mechanisms that allow changing the positional parameters of the headlamp module to accommodate tolerance stack-up and achieve optimal fit with adjacent vehicle components
2Manufacturing precision
If adjustable mechanisms are added to compensate for tolerance variations, then fit and finish quality is improved, but device complexity increases
Solution Approach 1:
The bracket is designed as a separate, modular component that provides adjustment capabilities independently from the headlamp module and vehicle body, isolating the complexity to a single replaceable part rather than requiring complex integrated systems
Solution Approach 2:
The bracket serves as an intermediary component between the headlamp module and the vehicle's front end structure, absorbing the complexity of adjustment mechanisms in this intermediate element rather than in the headlamp module itself or the vehicle body
3Manufacturing precision
If precise tolerances are maintained throughout the assembly, then fit and finish quality is improved, but manufacturing cost and difficulty increase
Solution Approach 1:
The bracket provides built-in parameter adjustment capabilities that allow operators to modify positional parameters after assembly, eliminating the need to maintain tight tolerances throughout the entire manufacturing chain and reducing manufacturing difficulty and cost
Data Source
AI summary
A slip plane bracket for a front end sub-assembly of a vehicle and method of assembling the front end of the vehicle is disclosed. The slip plane bracket attaches a headlamp module to a bolster at a front end of a vehicle to facilitate adjustment of the headlamp module location relative to the front fascia, headlamps and grille. Headlamp modules are assembled to a bolster through a slip plane bracket interface that is adjustable in X (longitudinal) and Y (lateral) directions to achieve improved fit relative to adjacent modules. According to the method, a pair of headlamp modules is attached to the bolster with an adjustable fastener to set the height of the modules. Slip plane brackets are assembled to tabs provided on the headlamp modules and the location of the slip plane brackets is adjusted in a longitudinal plane and a lateral plane.