Virtual Model Setup for Motor Vehicle Light Lens Joining
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Solution Overview
Problem
The existing methods for joining light lenses to motor vehicle housing in lighting arrangements are inefficient due to high time and effort expenditure, and a high risk of dimensional inaccuracies caused by imprecise setup of the joining apparatus, which relies on trial-and-error methods and multiple attempts to achieve a dimensionally accurate alignment.
Innovation Solution
A simulation-based method is introduced, where a virtual model of the joining apparatus is created to calculate the functional relationship between the relative arrangement of the light lens and housing, and the adjuster's displacement, allowing for the determination of a target displacement to achieve a dimensionally accurate setup through a single test construction unit, reducing the need for repeated measurements and adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If trial-and-error methods are used to set up the joining apparatus, then the setup process can be completed, but the time and effort expenditure is high and dimensional accuracy is compromised
Solution Approach 1:
The patent applies preliminary action by creating a virtual model of the joining apparatus before actual joining operations. The virtual model includes virtual holding device, receiving device, and adjuster that can be configured in advance to determine the correct relative positioning of light lens and housing, eliminating the need for repeated trial-and-error adjustments during actual production.
Solution Approach 2:
The patent uses a virtual copy (digital model) of the physical joining apparatus to simulate and determine the optimal setup configuration. This virtual model allows for iterative testing and optimization of the adjuster positioning without requiring physical trial-and-error joining operations, thereby reducing both time expenditure and achieving higher dimensional accuracy.
2Manufacturing precision
If multiple attempts are made to achieve dimensionally accurate alignment, then the joining accuracy improves, but the productivity decreases due to repeated measurements and adjustments
Solution Approach 1:
The virtual model enables preliminary determination of the correct adjuster positioning before actual joining. By pre-calculating the optimal configuration through virtual experimentation, the system eliminates repeated physical measurements and adjustments, allowing for single-attempt accurate joining that maintains both high precision and productivity.
Solution Approach 2:
The patent replaces the mechanical trial-and-error adjustment process with a computational simulation system. Instead of physically adjusting and measuring multiple times, the system uses virtual models and algorithms to calculate the precise adjuster displacement needed, substituting mechanical iteration with digital computation to achieve both accuracy and efficiency.
Data Source
AI summary
A method for setting up a joining apparatus for joining a light lens to a housing of a motor vehicle lighting arrangement. A first virtual model is created of the joining apparatus with a light lens and a housing received therein, a relative arrangement of the light lens to the housing corresponds to a target arrangement. A plurality of virtual models are created of the joining apparatus with the light lens and the housing received therein. The relative arrangement of the light lens to the housing deviates from the target arrangement in each case by means of virtual displacement of the adjuster. A target displacement is calculated of an adjuster on the basis of a functional relationship calculated and the relative arrangement in the test construction unit measured. A light lens is joined to a housing in the target arrangement by displacing the adjuster by the target displacement.