Tolerance-Compensating Frame for Dashboard Attachment
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Solution Overview
Problem
Manufacturing tolerances between A pillars in vehicles can lead to inconsistent distances, making it challenging to securely attach a dashboard support, as existing solutions are inefficient in compensating for these variations.
Innovation Solution
A tolerance-compensating element with a frame structure featuring a first and second fastening portion connected by lateral webs, equipped with a threaded nut for adjusting to different distances, allowing for flexible and resilient compensation through deformation, enabling secure attachment of the dashboard support to the vehicle body component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid fastening system is used to securely attach the dashboard support, then attachment strength is improved, but manufacturing tolerances cause gaps and misalignment that prevent proper installation
Solution Approach 1:
The frame structure is designed to change its rigidity parameter dynamically. During installation, the frame is flexible to accommodate manufacturing tolerances and bridge gaps. Once installed, it becomes rigid to provide secure attachment. This is achieved through the resilient design that allows deformation during mounting but maintains structural integrity during operation.
Solution Approach 2:
The fastening system transitions from a static rigid connection to a dynamic adaptable connection. The frame structure can deform elastically to compensate for distance variations between A pillars, then lock into a stable configuration. This dynamic behavior allows the same structure to accommodate tolerances during installation while providing strength during use.
2Reliability
If the frame structure is made rigid to ensure stability, then attachment reliability is improved, but adaptability to different distances caused by manufacturing tolerances deteriorates
Solution Approach 1:
The frame's rigidity parameter is changed based on the installation phase. During installation, the frame exhibits flexible behavior to adapt to varying distances between A pillars. After installation, the frame transitions to a rigid state to ensure reliable attachment. This parameter change is achieved through the resilient design that allows controlled deformation.
Solution Approach 2:
The frame structure automatically adjusts itself to compensate for manufacturing tolerances without requiring external adjustment mechanisms. The resilient design allows the frame to deform and adapt to the actual distance between A pillars during installation, then maintain this adapted configuration for reliable operation. The system self-adjusts based on the physical constraints it encounters.
3Adaptability or versatility
If the frame structure is made flexible to compensate for gaps, then adaptability to manufacturing tolerances is improved, but attachment strength and stability deteriorate
Solution Approach 1:
The frame structure exhibits dynamic characteristics where its mechanical properties change based on the installation process. Initially flexible to bridge gaps and accommodate tolerances, the frame then transitions to a stable rigid configuration once fastened. This dynamic transition allows the frame to provide gap compensation during installation while ensuring attachment strength during operation.
Solution Approach 2:
The resilient design of the frame structure provides beforehand cushioning for the gaps caused by manufacturing tolerances. The frame is pre-designed to be flexible in the region that needs to accommodate distance variations, allowing it to absorb and compensate for gaps before the final secure attachment is made. This cushioning effect enables subsequent strong fastening.
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
The solution effectively compensates for manufacturing tolerances, ensuring a secure and adjustable attachment of the dashboard support to the vehicle body, allowing for precise alignment and deformation to bridge gaps of a few millimeters, thereby enhancing the stability and reliability of the attachment.
Implementation Method 1
the frame structure is of resilient design. An efficient compensation for gaps can be brought about by means of a spring deflection of the frame structure.
Data Source
AI summary
The disclosure relates to a tolerance-compensating element for compensating for a distance between a dashboard support and a body component of a vehicle, such as an A pillar or an end wall, wherein the dashboard support is connectable to the body component by means of a fastening screw, comprising: a frame structure with a first fastening portion and a second fastening portion, wherein the first fastening portion and the second fastening portion are arranged opposite each other and are connected by lateral webs, wherein the first fastening portion and the second fastening portion are spaced apart from each other, wherein a first aperture is formed in the first fastening portion, wherein the second fastening portion is configured for fastening the tolerance-compensating element to the dashboard support; and a threaded nut that is assigned to the first fastening portion and is provided for receiving the fastening screw.