Vehicle Panel Coupler for Edge Alignment Without Distal Access
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Solution Overview
Problem
The assembly of vehicle exterior parts, such as fascia and fenders, is challenging due to the inaccessibility of the distal ends, which complicates the alignment and securing process, leading to increased assembly time and complexity.
Innovation Solution
A vehicle assembly system that includes a bracket attached to one of the panels and a coupler with a proximal and distal end portion, where the distal end portion is movable relative to the panels as the proximal end is secured, allowing edges to align without requiring access to the distal ends, thus simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening methods are used to secure fascia and fender edges together, then the panels can be firmly joined, but the distal ends become inaccessible requiring complex assembly procedures and increased assembly time
Solution Approach 1:
The fastening system is divided into two functional segments: a proximal portion that is accessible and can be easily fastened, and a distal portion that is inaccessible. The bracket and coupler are positioned at the proximal end, allowing the fastening function to be separated from the location that requires accessibility, thus solving the contradiction between joint strength and assembly time.
Solution Approach 2:
A bracket-coupler intermediary mechanism is introduced between the fascia and fender panels. This intermediary system translates fastening actions performed at the accessible proximal location into effective joining forces at the inaccessible distal edges, eliminating the need for direct access to the distal ends while maintaining joint integrity.
2Manufacturing precision
If fasteners are placed at distal ends of panels to secure edges together, then proper alignment can be achieved, but the assembly process becomes complex due to inaccessibility of those locations
Solution Approach 1:
Instead of placing fasteners at the distal ends where edges meet, the fastening mechanism is inverted and positioned at the proximal ends of the panels. The bracket attaches to one panel and the coupler to the other, both at accessible proximal locations, reversing the conventional fastening location while maintaining alignment functionality.
Solution Approach 2:
The fastening action is moved from the distal-dimensional location (where edges meet) to the proximal-dimensional location (where access is available). This spatial dimensionality change allows the same alignment function to be achieved at a different location in the panel assembly, simplifying the assembly process while maintaining precision.
3Ease of manufacture
If direct fastening at distal ends is attempted, then edges can be secured together, but accessibility requirements increase assembly complexity and time
Solution Approach 1:
The bracket and coupler are pre-positioned at the proximal ends of the panels before the final assembly step. This preliminary positioning establishes the correct geometry and alignment relationships early in the assembly process, allowing the distal edges to be brought together reliably without requiring access to those locations during the fastening operation.
Data Source
AI summary
An assembly for a vehicle and a method of assembling the vehicle are disclosed. The assembly includes a first panel and a second panel. The first panel includes a first edge and the second panel includes a second edge generally aligning with the first edge of the first panel. The assembly also includes a bracket attached to one of the first and second panels. The assembly further includes a coupler engaging the bracket. The coupler includes a proximal end portion and a distal end portion. The distal end portion is movable with respect to one of the first and second panels as the proximal end portion is secured to the other one of the first and second panels such that one of the first and second edges moves toward the other one of the first and second edges.