Tolerance-Equalizing Element Using Rectangular-Wire Helical Springs
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Solution Overview
Problem
Existing tolerance compensation members require labor-intensive machining processes and are costly to manufacture, limiting their efficiency and cost-effectiveness in forming tensed connections between construction members.
Innovation Solution
The use of helical springs with non-rectangular cross-sections wound to form screw threads eliminates the need for cutting-type machining, allowing for the formation of high-strength support bodies that can be easily adjusted to compensate for large distance tolerances without extensive mill cutting, and optional welding or gluing of turns for added rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cutting-type machining processes (milling or thread cutting) are used to form support bodies, then manufacturing precision and strength can be achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The invention changes the manufacturing method from cutting-type machining to winding-type forming. By winding wire with specific cross-sectional profiles (rectangular, L-shaped, T-shaped, etc.) into helical springs, the support bodies are formed without requiring complex milling or thread cutting operations. This parameter change in the manufacturing process eliminates laborious machining while maintaining the required strength and precision through the geometric properties of the wound wire structure.
2Ease of manufacture
If helical springs are used as support bodies, then ease of manufacture and cost reduction are achieved, but manufacturing precision and supporting force may be compromised
Solution Approach 1:
The invention applies local quality by designing the wire cross-section with specific geometric features at critical locations. The wire is given non-circular cross-sections (rectangular, L-shaped, T-shaped) where the local geometry creates precise threaded engagement surfaces. The winding process forms external threads on one helical spring that precisely mate with internal threads formed by the groove structure of the other helical spring, achieving manufacturing precision through localized geometric design rather than uniform machining.
3Force
If high-strength spring steels are used in helical springs, then supporting force is increased, but manufacturing complexity increases due to material requirements
Solution Approach 1:
The invention changes the material parameter by selecting high-strength spring steels with specific mechanical properties suitable for winding into helical springs. The material is chosen to provide the necessary elastic properties and strength for the tolerance compensation function. The wire diameter and cross-sectional profile are optimized to achieve the required supporting force while maintaining manufacturability through standard spring winding processes, balancing material strength with manufacturing simplicity.
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
This approach simplifies the manufacturing process, reduces costs, and enables a high supporting force over a small axial distance, allowing for a large adjustment range and effective compensation of distance tolerances, even at the minimum axial dimension.
Implementation Method 1
one support body is formed by a helical spring that is wound from a wire
Implementation Method 2
the support body is entrained frictionally and is thereby rotated relative to the other support body
Data Source
AI summary
A tolerance equalizing element includes at least two support bodies (120, 122) which are in threaded engagement with one another such that the axial dimension of the tolerance equalizing element can be adjusted by relative rotation of the support bodies (120, 122), at least one of the support bodies (120, 122) including a helical spring which is wound from a wire having a rectangular cross-section, and the rectangle forming the cross-section of the wire is oriented such that its sides extend obliquely relative to the axis of the helical spring.