Elastically Deformable Wiring Harness Alignment and Retention
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Solution Overview
Problem
Current alignment systems for components, such as those in automotive vehicles, face issues with positional variation due to oversized or undersized alignment features, leading to misalignment and a loose fit, which affects the functionality and aesthetic quality of assemblies, particularly in flexible assemblies like electrical wiring harnesses.
Innovation Solution
An elastically averaged alignment and retention system using elastically deformable elements that engage with corresponding alignment features to provide precise alignment and retention in multiple directions, minimizing manufacturing variances and ensuring a secure fit through elastic deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate alignment features and fasteners are used, then alignment and securement functions are provided, but the effectiveness of each is limited and components can still rattle and vibrate
Solution Approach 1:
The patent combines alignment features and retention fasteners into a single integrated component. The alignment feature includes both the alignment portion that locates components and the retention portion that secures them, eliminating the need for separate fasteners and improving overall effectiveness while reducing component count.
Solution Approach 2:
The alignment feature is designed to perform multiple functions simultaneously: it provides alignment during assembly and continues to provide retention and vibration prevention after assembly. This multi-functional design replaces the need for separate alignment and retention components.
2Reliability
If tree-type fasteners are used for retention, then components are prevented from separating, but the loose fit allows components to rattle and vibrate
Solution Approach 1:
The retention portion of the alignment feature is designed with specific local characteristics including engagement geometry and interference fit dimensions that provide both secure retention and vibration resistance. The local quality of the engagement interface is optimized to prevent both separation and rattling.
Solution Approach 2:
The patent specifies precise parameter ranges for the interference fit, including dimensional tolerances and material properties, to achieve both secure retention and vibration resistance. By controlling parameters like interference dimension and material elastic modulus, the design achieves both retention security and stability.
3Ease of operation
If oversized alignment features are used to provide spacing, then components can move freely for alignment, but significant positional variation occurs between mated components
Solution Approach 1:
The patent uses elastic deformation of the alignment feature during assembly to compensate for manufacturing tolerances. The elastic material deforms to accommodate positional variations and then maintains a precise final position, achieving both ease of alignment and manufacturing precision through controlled elastic parameters.
Solution Approach 2:
The elastic alignment feature is designed to absorb and compensate for manufacturing variations before final assembly. The elastic deformation acts as a cushion that accommodates tolerances and ensures precise final positioning, preventing the propagation of manufacturing errors to the assembled product.
4Ease of manufacture
If clearance is provided between alignment features to match manufacturing tolerances, then assembly is facilitated, but misalignment affects function and appearance of the entire assembly
Solution Approach 1:
The elastic alignment feature changes its dimensional parameters during assembly through elastic deformation. It starts with a larger effective dimension to facilitate assembly and then deforms to achieve a precise final dimension, simultaneously achieving ease of manufacture and manufacturing precision.
Solution Approach 2:
The alignment feature transitions from a static clearance-based design to a dynamic elastic deformation design. The feature actively deforms during assembly to accommodate tolerances and then maintains a precise final position, providing both assembly facilitation and alignment precision through its dynamic response.
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
The system achieves precise alignment and retention in multiple directions, reducing positional variation and vibration, thereby enhancing the functional stability and aesthetic quality of assemblies by utilizing elastically deformable elements that adapt to interference fits.
Implementation Method 1
The elastically deformable alignment and retention element is configured and disposed to interferingly, deformably and matingly engage the alignment and retention feature. Portions of the elastically deformable alignment and retention element when inserted into the alignment and retention feature elastically deform to an elastically averaged final configuration that aligns and retains the first component relative to the second component
Data Source
AI summary
An elastically averaged alignment and retention system includes a first component having a first alignment member and an elastically deformable alignment and retention element, and a second component having a second alignment member and an alignment and retention feature. The first alignment member includes an electrical wiring harness, the elastically deformable alignment and retention element includes a hollow tube, the second alignment member includes a support for the electrical wiring harness, and the alignment and retention feature includes an aperture. The elastically deformable alignment and retention element is configured and disposed to interferingly, deformably and matingly engage the alignment and retention feature. Portions of the elastically deformable alignment and retention element when inserted into the alignment and retention feature elastically deform to an elastically averaged final configuration that aligns and retains the first component relative the second component in at least two of six planar orthogonal directions.