Vehicle AC Coupling Assembly Segmentation
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Solution Overview
Problem
The production of coupling assemblies for vehicle air-conditioning units is complex and costly, requiring complete replacement of tubular and coupling component assemblies for different connecting components, limiting flexibility and efficiency.
Innovation Solution
A coupling assembly with a separate coupling component that locks onto a tubular component using a rotationally fixed connection, allowing for flexible manufacturing and application, with the option to connect the same tubular component to different connecting parts using various coupling components, and featuring a form-fitting connection for precise alignment and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tubular component with an injection-molded coupling component is used, then the coupling assembly is integrated and structurally sound, but the production becomes complex and costly, and flexibility to connect to different connecting parts is reduced
Solution Approach 1:
The coupling assembly is divided into separate components: a tubular component and a separate coupling component. The tubular component can be manufactured independently using standard processes, and the coupling component is manufactured separately and then attached to the tubular component. This segmentation simplifies production while maintaining structural integrity through the locking connection mechanism.
2Ease of manufacture
If a tubular component with an injection-molded coupling component is used, then the assembly is complete, but the cost increases and flexibility to adapt to different connecting parts decreases
Solution Approach 1:
The separate coupling component is designed as a universal interface that can be attached to various tubular components and connected to different types of connecting parts. The standardized locking connection and form-fitting features enable the same coupling component to adapt to multiple connecting part configurations, enhancing versatility while keeping manufacturing simple.
3Volume of moving object
If tubular components and coupling components are transported separately, then the transport volume is reduced, but additional assembly steps are required
Solution Approach 1:
The coupling assembly is segmented into tubular components and separate coupling components that can be transported independently in optimized packaging configurations, reducing overall transport volume. The components are designed with self-aligning features and simple locking mechanisms that enable quick and intuitive assembly at the destination without requiring complex tools or procedures.
4Stability of the object's composition
If a rotationally fixed connection is added to prevent rotation of the tubular component, then the connection stability is improved, but the device complexity increases
Solution Approach 1:
The rotationally fixed connection utilizes asymmetric geometric features such as non-circular cross-sections, flattened areas, or bulged sections on the tubular component that mate with corresponding features on the coupling component. This asymmetric design prevents rotational movement while maintaining a relatively simple connection structure that integrates well with the overall coupling assembly.
Data Source
AI summary
A coupling assembly (10) for a vehicle air-conditioning unit comprises a tubular component (12) and a coupling component (14) for coupling the tubular component (12) to a connecting part (16), whereby the coupling component (14) constitutes a separate component that can be inserted into the tubular component (12), which is connected to tubular component (12) by a locking connection (24). A method of coupling a tubular component (12) of a vehicle air-conditioning unit to a connecting part (16) that includes the following steps: Provision of tubular component (12), connecting part (16) and a separate coupling component (14); attachment of the coupling component (14) to the end of the tubular component (12) and attachment of coupling component (14) on the tubular component (12) by means of a locking connection (24); and insertion of the coupling component (14) fixed to the tubular component (12) in the connecting part (16), and attachment of the coupling component (14) to the connecting part (16).