Tolerance Compensator Fastening System for Automotive Dashboard
Solution Overview
Problem
Existing tolerance compensators for fastening dashboard supports to vehicle frames are heavy, costly, and prone to deformation due to manufacturing tolerances and require excessive material, leading to inefficiencies in weight and cost.
Innovation Solution
A lightweight tolerance compensator comprising a collar or washer screw and two independent nuts with different diameters, featuring inner friction-retaining elements and alternating threaded and non-threaded sectors, allowing for variable distance adaptation without deforming the dashboard or pillar, and constructed to minimize material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cylindrical tube spacer is used with soldering and long axle screws, then fastening of dashboard supports to vehicle frame is achieved, but the assembly weight increases and manufacturing cost increases
Solution Approach 1:
The tolerance compensator is divided into multiple functional components: an outer nut with external threading, an inner nut with internal threading and friction-retaining elements, and alternating threaded and non-threaded sectors. This segmentation allows each component to perform its specific function efficiently, reducing the need for excessive material in any single part while maintaining overall fastening reliability.
Solution Approach 2:
The inner nut is nested within the outer nut, with the inner nut's outer diameter being smaller than the outer nut's inner diameter. This nested configuration allows the friction-retaining elements of the inner nut to engage with the screw shaft while the outer nut provides structural support and threading engagement, achieving weight reduction through optimized material distribution.
2Reliability
If a cylindrical tube spacer is used with specified tightening torque, then secure fastening is obtained, but deformation of the pillar occurs in coupling areas
Solution Approach 1:
The tolerance compensator incorporates dynamic adjustment capability through the interaction between the inner and outer nuts. The friction-retaining elements allow the inner nut to self-adjust its position along the screw shaft, accommodating manufacturing tolerances and variable distances between fastening points. This dynamic adaptation eliminates the need for excessive tightening torque, preventing pillar deformation while maintaining fastening security.
Solution Approach 2:
The device changes the mechanical parameters of the fastening system by introducing friction-based retention instead of relying solely on high torque. The friction coefficient between the inner nut's retaining elements and the screw shaft provides a controlled resistance that maintains fastening security at lower torque levels, thereby preventing deformation of the pillar.
3Adaptability or versatility
If manufacturing margins are considered for variable separation distance, then adaptation to tolerance variation is enabled, but material usage increases
Solution Approach 1:
The inner nut features localized friction-retaining elements only in specific sectors where adaptation is needed, rather than providing uniform material distribution throughout. The alternating threaded and non-threaded sectors create local zones of friction engagement that enable tolerance adaptation with minimal material usage. This local quality approach ensures adaptability to variable distances without requiring excessive material in the entire component.
4Weight of moving object
If two independent nuts with alternating threaded and non-threaded sectors are used, then weight and material cost are reduced, but device complexity increases
Solution Approach 1:
The inner and outer nuts are designed to work together as an integrated tolerance compensator system. The outer nut provides the primary threading engagement with the screw, while the inner nut with its friction-retaining elements provides tolerance adaptation. By merging these two functions into a coordinated dual-nut system, the patent achieves weight reduction through optimized material distribution while the interaction between the nuts simplifies the overall assembly process compared to using multiple separate adjustment components.
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 provides a lightweight, cost-effective fastening system that adapts to variable distances without deformation, significantly reducing material weight and manufacturing costs while ensuring secure fastening.
Implementation Method 1
the smaller nut being provided with friction-retaining inner devices that act against the threading of the screw
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
TOLERANCE COMPENSATOR, of the type used to attain the fastening of two elements together that may be located at a slightly variable distance, which is utilized, for instance, in automobile vehicles and is formed, at least, by an inner nut (3) and an outer nut (4), in which said inner nut (3) can a sheet coiled on itself, it being fitted with at least two threaded perimeter sectors (8) for said outer nut (4); at least one side thereof also being the support for respective retaining elements towards the inside of said inner nut (3) that provide friction spots against said threading (7) of said screw (2).