Vehicle Surface Simulation Jig for Water Spray Pattern Mapping
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Solution Overview
Problem
Current water leak testers face inconsistencies in verifying water distribution patterns, especially for non-vertical sprays, and are incompatible with conveyor-based systems, leading to inaccurate testing and inability to produce a comprehensive map of water distribution across vehicle exteriors.
Innovation Solution
A vehicle surface simulation apparatus comprising a jig with adjustable planar areas and water collection assemblies that simulate specific vehicle profiles, allowing for precise measurement and recording of water distribution patterns, compatible with both static and conveyor-based testers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional water leak testers use fixed spray patterns, then the testing process is simple, but the accuracy of water distribution mapping is insufficient
Solution Approach 1:
The testing system is segmented into multiple adjustable spray zones with individual nozzles that can be independently positioned and angled. Each zone can be calibrated separately to map water distribution across different vehicle surface areas, enabling precise measurement without requiring a complete system redesign.
Solution Approach 2:
The system allows dynamic adjustment of spray parameters including nozzle angle, position, and spray pattern intensity. These parameters can be modified to optimize water distribution mapping for different vehicle types and test conditions, improving measurement precision while maintaining operational flexibility.
2Adaptability or versatility
If water leak testers are designed for static vehicles only, then the nozzle configuration is simple, but the adaptability to conveyor-based systems is lost
Solution Approach 1:
The nozzle assembly is designed with universal mounting capabilities that allow the same configuration to be used on both static vehicle platforms and conveyor-based systems. The adjustable positioning mechanism enables the nozzles to adapt to moving vehicles on conveyors while maintaining the same spray patterns and coverage areas.
Solution Approach 2:
The system incorporates dynamic adjustment capabilities where nozzle positions and angles can be modified during operation to accommodate different vehicle speeds on conveyors. This dynamic adaptability allows the tester to maintain effective spray patterns whether the vehicle is stationary or moving through the testing chamber.
3Measurement precision
If comprehensive water distribution mapping is implemented, then the testing accuracy is improved, but the time required for calibration and measurement increases
Solution Approach 1:
The system includes pre-configured nozzle assemblies with predetermined spray patterns that are calibrated in advance for different vehicle types. This preliminary calibration reduces the time required during actual testing, as the mapping parameters are already optimized and ready for immediate use without extensive on-site adjustment.
Solution Approach 2:
The system incorporates feedback mechanisms that automatically adjust spray patterns based on real-time measurement data. This closed-loop control enables the system to rapidly converge on accurate water distribution mappings without requiring multiple manual calibration cycles, significantly reducing the total calibration and measurement time.
Data Source
AI summary
A vehicle surface simulation apparatus for mapping a nozzles spray pattern of a water leak tester configured to spray water onto an exterior of a vehicle. A jig of the apparatus can be configured to simulate a plurality of exterior surface portions of two different vehicles. The jig can include at least a first area configured to represent at least a portion of a side-view profile of the first vehicle and the second vehicle, and at least a second area configured to represent at least a portion of a front-view profile of the first vehicle and at least a portion of a rear-view profile of the second vehicle. The funnel can be supported in one of the areas such that a funnel inlet lies in a plane that represents a predetermined surface of the vehicle. The conduit can be in fluid communication with the funnel and the container.