Portable Vehicle Panel Deflection Test Device
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Solution Overview
Problem
Existing vehicle body panel deflection testing is time-consuming and prone to variation due to complex setup requirements, involving multiple manual adjustments and the use of dial indicators.
Innovation Solution
A test device comprising a frame with handles, a force applicator, a force sensor, and non-contact sensors, which allows for quick and accurate measurement of panel deflection by applying forces and detecting distances without physical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual dial indicators and complex frames are used for testing, then measurement precision can be achieved, but testing time and setup complexity increase significantly
Solution Approach 1:
The patent replaces manual dial indicators and mechanical measurement systems with electronic force sensors and digital data acquisition systems. This substitution eliminates the need for manual reading and recording, enabling automated data collection and reducing testing time while maintaining measurement precision through electronic detection and digital processing.
Solution Approach 2:
The patent changes the measurement parameters from mechanical dial readings to electronic sensor signals. Force sensors convert physical deflection into electrical signals that can be processed by data acquisition modules, enabling faster data collection and eliminating the time-consuming manual operations associated with traditional mechanical measurement systems.
2Measurement precision
If complex frames and multiple setup components are used, then measurement accuracy is maintained, but device complexity and ease of operation deteriorate
Solution Approach 1:
The patent merges multiple separate components (force sensors, data acquisition modules, display devices) into an integrated testing system. The force applicator incorporates both force sensing and data acquisition capabilities within a single device structure, eliminating the need for multiple separate instruments and reducing setup complexity while maintaining measurement precision through integrated electronic systems.
Solution Approach 2:
The patent creates a universal testing device that can measure both force and deflection parameters using the same apparatus. The force applicator serves multiple functions: applying test forces, sensing the forces through mounted sensors, and acquiring data through integrated modules. This multi-functionality reduces the need for specialized equipment for each measurement type, simplifying the overall device complexity.
3Adaptability or versatility
If manual force gauges and repeated setup are used for each location, then comprehensive testing is achieved, but productivity and consistency deteriorate
Solution Approach 1:
The patent replaces manual force gauge operations with automated electronic force sensors and data acquisition systems. This automation enables rapid sequential testing at multiple locations without requiring manual setup and measurement operations for each test point, significantly improving productivity while maintaining comprehensive testing coverage through systematic data collection.
Solution Approach 2:
The patent enables continuous testing operations by eliminating the need to dismantle and reconfigure the apparatus between test locations. The portable force applicator with integrated sensors can be quickly repositioned and immediately begin measurement, maintaining continuous productive action across multiple test points rather than interrupting with repeated setup procedures.
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
Facilitates rapid and consistent testing of multiple vehicle body panel locations with reduced setup time and variation, providing precise deflection measurements.
Implementation Method 1
The force sensor is configured to detect a push and/or pull force applied via the force applicator to a location on an object
Implementation Method 2
the at least one non-contact sensor includes a stereoscopic camera
Data Source
AI summary
A test device and method can include a frame, a force applicator, and a force sensor. The frame includes a first handle, second handle, and main body. The handles extend from a perimeter of the main body and are configured to be gripped by an operator's hands. The main body includes a housing portion and support portion. The housing portion is configured to hold a display device such that a display screen of the display device is visible from a rear side of the main body. The support portion is disposed on a front side of the main body. The force applicator extends forward away from the support portion. The force sensor is mounted to the support portion and couples the force applicator to the support portion. The force sensor is configured to detect a push and/or pull force applied via the force applicator to a location on an object.