Swaged Vehicle Door Frame Joint Alignment
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Solution Overview
Problem
The existing swaging process for joining vehicle door frame members often results in misalignment, leading to inaccurate positioning and reduced coupling strength due to the relative position of the inner and outer members becoming out of alignment during the clamping and folding process.
Innovation Solution
A swaged structure design featuring a first member with a plate part and a groove, and a second member with an end portion having a recess and projection, where the projection engages the recess to ensure accurate alignment and increased coupling strength by pressing the plate part to narrow the groove opening, allowing for precise positioning and enhanced mechanical interlock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the edge of the outer member is clamped and swaged to join the inner and outer members, then the members are coupled together, but the relative position of the inner member and outer member becomes out of alignment
Solution Approach 1:
The groove is formed on the outer member before the swaging process, and the projection on the inner member is designed to fit into this groove. This preliminary structural preparation ensures that when the swaging process is performed, the members are already pre-positioned correctly, preventing misalignment while maintaining coupling strength
Solution Approach 2:
The groove and projection structure acts as an intermediary positioning mechanism between the inner and outer members. This intermediate feature guides the relative positioning of the two members during the swaging process, ensuring accurate alignment before the final coupling is achieved
Data Source
AI summary
The end portion of a first member includes a plate part and a groove. The end portion of a second member includes an edge and two side surfaces. The groove extends around the edge of the second member and the two side surfaces. The groove includes a side surface including an engaging portion. One of the side surfaces of the end portion of the second member includes an engaged portion. A method for manufacturing a swaged structure includes preparing the first member including the plate part and the groove having a wide opening. The method further includes inserting the end portion of the second member into the groove after preparing the first member. The method further includes pressing the plate part in a direction narrowing the opening of the groove to bring the engaging portion into contact with the engaged portion after inserting the second member.