Trunk Lid Panel Alignment Jig for Single-Process Laser Brazing
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Solution Overview
Problem
Conventional trunk lid assembly processes are complex, time-consuming, and result in poor assembly quality due to the need for multiple jigs and the use of plastic back panel moldings, which increase weight, cost, and complicate design freedom.
Innovation Solution
A jig apparatus that aligns and fixes the upper, extension, and lower panels in a single process using tilting-rotatable and linearly movable activation jig units, enabling laser brazing for efficient assembly and reducing the need for additional jigs and plastic moldings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple process jigs are used to align and weld panels, then the assembly process can be completed, but the assembly time and handling cycle time increase significantly
Solution Approach 1:
The patent combines multiple process jigs (first process jig for upper panel alignment and second process jig for lower panel alignment) into a single integrated jig apparatus. This unified jig allows simultaneous alignment and fixation of both upper and lower panels, eliminating the need to transfer panels between separate jigs and thereby reducing handling cycle time while maintaining assembly precision.
2Productivity
If panels are aligned and fixed in different process jigs, then the assembly can be completed, but the assembly quality and panel centering deteriorate
Solution Approach 1:
The jig apparatus is designed with multi-functional capabilities to perform both upper panel alignment (via first activation jig unit) and lower panel alignment (via second activation jig unit) within a single device. This universal jig maintains consistent reference standards for all panels, ensuring high assembly quality and accurate panel centering without the errors that would arise from using separate jigs with potentially different reference frames.
3Productivity
If plastic back panel molding is used in trunk lid assembly, then the assembly structure is complete, but the weight and material cost increase
Solution Approach 1:
The patent extracts and eliminates the plastic back panel molding from the traditional assembly structure. By removing this non-essential component, the invention achieves the same structural completeness through alternative means (direct panel assembly with bonding and welding) while significantly reducing the overall weight and material cost of the trunk lid assembly.
4Productivity
If conventional spot welding and plastic molding are used, then the assembly is complete, but the design freedom and cost efficiency are reduced
Solution Approach 1:
The patent changes the bonding method from conventional spot welding to laser bonding technology. This parameter change in the joining process enables greater design freedom by allowing more flexible panel configurations and geometries that are difficult to achieve with traditional spot welding, while also improving cost efficiency through automated laser processing and elimination of plastic molding operations.
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
Simplifies the assembly process, reduces assembly time and costs, and improves the quality of the trunk lid by allowing for single-process alignment and laser brazing of panels, minimizing handling errors and enhancing design flexibility.
Implementation Method 1
welding these panels through laser brazing
Data Source
AI summary
A jig apparatus is used for assembling a trunk lid including an upper panel, an extension panel, and a lower panel. The jig apparatus may include: a jig frame; a first activation jig unit configured to align and fix the upper panel and the extension panel and installed at the jig frame in front and rear directions to be tilting-rotatable; and a second activation jig unit aligning and fixing the lower panel and installed at the jig frame to be linearly movable in the front and rear directions with respect to the first activation jig unit.