Vehicle Window Fit Evaluation Using Illuminated Gap Detection
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Solution Overview
Problem
Existing methods struggle to accurately assess the fit between a modular vehicle window assembly and its intended opening in a vehicle body, particularly failing to detect subtle discrepancies that can lead to quality issues during assembly.
Innovation Solution
An apparatus with a vehicle body opening simulator equipped with high-intensity LED lighting and adjustable clamping mechanisms, allowing for precise evaluation of the fit by illuminating gaps between the window assembly and the simulated opening, enabling early detection and correction of potential defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If unaided visual observation is used to assess fit, then the method is simple and quick, but subtle fit discrepancies cannot be detected
Solution Approach 1:
The patent introduces light as an intermediary substance to enhance the visibility of gaps between the window assembly and body opening. The light sources illuminate the interface region, making subtle discrepancies visible without requiring complex measurement instruments, thus resolving the contradiction between detection accuracy and device complexity.
Solution Approach 2:
The patent utilizes lighting to create visual contrast and highlight gaps through illumination differences. By strategically positioning light sources, the apparatus creates visible variations in brightness that reveal fit discrepancies, enabling precise detection while maintaining simplicity of the evaluation system.
2Measurement precision
If multiple light sources are added to illuminate gaps, then visibility of fit discrepancies is enhanced, but device complexity increases
Solution Approach 1:
The patent divides the illumination system into multiple discrete light sources positioned at specific locations around the periphery of the simulated body opening. Each light source illuminates a specific segment or region, allowing comprehensive coverage of potential gap areas while maintaining modular simplicity in the overall apparatus design.
3Reliability
If pre-production testing is increased to minimize assembly line problems, then quality of fit and finish is improved, but production time and cost increase
Solution Approach 1:
The patent implements a simulated body opening apparatus that enables pre-production testing of window assembly fit before actual vehicle assembly. By performing fit evaluation earlier in the development process using this dedicated testing device, manufacturers can identify and correct issues before they reach the production line, improving quality while actually reducing overall production time through early defect detection.
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
Enhances the visibility of subtle fit discrepancies, allowing for timely corrective actions to minimize defects and improve the quality of the assembly process, ensuring a precise and accurate evaluation of the modular vehicle window assembly's fit into the vehicle body opening.
Implementation Method 1
by providing at least one, but preferably a plurality of light sources in light transmitting openings formed in predetermined locations in a recessed cavity portion of the vehicle body opening/sheet metal simulator it is possible to greatly enhance the visibility of 'gaps' between the peripheral edges of the modular vehicle window assembly and the vehicle body opening
Data Source
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AI summary
An apparatus (10) for evaluating the fit of a modular window assembly (20) into a simulated vehicle body opening (16) includes a base member (12), a vehicle body opening/sheet metal simulator (14) mounted to the base member, one or more light sources disposed in the vehicle body opening/sheet metal simulator (14) and one or more devices for securing the vehicle window (20) to the vehicle body opening/sheet metal simulator (14). A method of utilizing the apparatus (10) is also a part of the invention.