Note: Descriptions are shown in the official language in which they were submitted.
CA 02803709 2013-01-25
METHOD FOR INSTALLING WORK-PIECE TO MATING STRUCTURE, AND
APPARATUS
[000.1] = TECHNICAL FIELD
[0002] Aspects generally relate to a method for installing a work-piece to
a mating
structure, and/or associated apparatus therefor and/or therof.
[0003] BACKGROUND
[0004] A work-piece is an object, assembly, etc., that is worked on with a
tool or
machine; an example of a work-piece is a headlight assembly.
[0005] A mating structure is a structure that is to be mated (joined,
installed) to the work-
piece; an example of the mating structure is a vehicle (such as a car Or
truck).
=
[0006] SUMMARY
=
[0007] I, the inventor, have researched a problem associated with known
fixture
assemblies and work-pieces. After much study, I believe I have arrived at an
understanding of the problem and its solution(s), which are stated below.
[0008] Fit and finish pertain to the evaluative standard of a vehicle's
cosmetic
appearance. Good fit and finish means (for example) that (generally speaking)
the body
panels and trim are evenly spaced, aligned, and secure, and/or the paint is
evenly applied
with no bubbles or pit marks; in other words, the assemblies that have
surfaces that are
visible by the human eye pertain to fit and finish surfaces.
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[0009]
In the automobile manufacturing industry, the term fit and finish refers
to the way
the parts of a car go together. For example, the hood should join smoothly
with the fender
of the car, so that neither sticks out and the gaps between them are barely
visible. The
paint job should be smooth and even, with no unintended variations in color.
The
upholstery should sit firmly on the seats with no untrimmed edges. The doors
should
close tightly. If these things (amongst other things) are so, the car has a
perfect fit and
finish, and that means a lot.
=
[00010] When a customer looks at a car with an eye toward buying it, he or she
may not
consciously notice the fit and finish. In fact, chances are good that the
potential buyer
may be more concerned over what kind of mileage the car gets or how powerful
the
engine is. However, there is an unconscious visual assessment of the entire
vehicle
= underway as the potential buyer inspects the car. On some level the buyer
is aware that if
the manufacturer got the fit and finish right, then they care about details
and probably got
other things right as well.
[00011] An imperfect fit and finish can hurt sales of cars. So there are
entire departments
at car manufacturers that work almost exclusively with fit and finish issues,
using
sophisticated, high-tech machinery that analyzes the way parts fit together on
the level of
one or two millimeters. The machinery used on modern assembly lines to analyze
fit and
finish may include laser beams, robotic eyes, and a combination of humans and
computers doing the actual final inspection. In recent years, the auto
industry has
partnered with the National Institute for Standards and Technology (NIST) to
improve its
ability to measure fit and finish.
[00012] It would be a serious misstep to not pay enough attention to quality
control issues
like fit and finish. Controlling fit and finish issues may be usually
addressed by applying
=
= stringent quality control measures to make sure cars have acceptable fit
and finish. Major
auto makers have quality control departments, often staffed by experts in
metrology, the
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= Science of measurement. These experts have brought with them
sophisticated measuring
= tools that can check (almost instantly) the precise dimensions of cars
and sub-assemblies
= as they move down the production line. The most advanced of these tools
use laser
triangulation to produce a three-dimensional model of the components, so that
they can
be checked by a computer (or by a human computer operator) to determine if,
say, a door
doesn't close tightly enough. If so, the entire assembly line can be shut down
until =
someone determines what went wrong and fix the problem. These laser scanners
can be
attached to robotic arms in the factory so that they can perform their job
without a human .
=
being present. They can detect small variations based on a predefined CAD
(computer-
aided-design) rnodel already stored in the computer's memory.
[00013] In the late 1990s, the American auto industry joined forces with the
National
Institute for Standards and Technology (NISI; formerly the Bureau of
Standards) to
produce what was known as the "2-millimeter assembly process," which could
hold
dimensional variations in auto assembly, which had previously been accurate
only within
or 6 millimeters, to within less than 2 millimeters. The result, according to
some
.observers, was an immediate improvement in fit and finish of cars.
[00014} Fit and finish isn't just about perceived quality, of course. If
there's a gap between
1 the door and the rest of the car's body, air can come
whistling through noisily as you
drive and produce a chilling interior wind in cold weather. And rain can leak
into the ear,
damaging the upholstery or getting passengers wet. It can even ruin the
aerodynamic =
= profile of the vehicle. So poor fit and finish has very practical
consequences, too.
[00015] Automobile manufacturers should (therefore) not ignore fit and finish
issues.
[00016] In order to mitigate the above, at least in part, in accordance with
an aspect of my
work, I (the inventor) have developed an apparatus including a Work-piece. The
work-
piece has a critical surface associated with a fit-and-finish surface. The
apparatus also
3
=
= HON-MD/CDA
CA 02803709 2013-01-25
= =
includes a mating structure. The apparatus also includes a datum having a
first portion
= interfaced with the work-piece. The datum also has a second portion
interfaced with the
mating structure. The datum is adjusted in such a way that the datum
facilitates
. .
placement of the critical surface within acceptable tolerance to the fit-and-
finish surface
= once (A) the datum is placed between the work-piece and the mating
structure, and (B)
the work-piece is installed to the mating structure.
[00017] In order to mitigate the above, at least in part, in accordance with
an aspect of my
work, I (the inventor) have developed an apparatus including a datum. The
datum has a
first portion configured to interface with a work-piece having a critical
surface associated
with a fit-and-finish surface. The datum also has a second portion configured
to interface
with a mating structure. The datum is adjusted in such a way that the datum
facilitates
placement of the critical surface within acceptable tolerance to the fit-and-
finish surface
once (A) the datum is placed between the work-piece and the mating structure,
and (B)
the work-piece is installed to the mating structure.
=
[000181 In order to mitigate the above, at least in part, in accordance with
an aspect of my
work, I (the inventor) have developed an apparatus including a work-piece
having a
critical surface associated with a fit-and-finish surface. The apparatus also
includes a
datum having a first portion interfaced with the work-piece. The datum also
has a second
portion configured to interface with a mating structure. The datum is adjusted
in such a
way that the datum facilitates placement of the critical surface within
acceptable
=
tolerance to the fit-and-finish surface once (A) the datum is placed between
the work-
piece and the mating structure, and (B) the work-piece is installed to the
mating structure.
[00019] In order to mitigate the above, at least in part, In accordance with
an aspect Of my
work, I (the inventor) have developed an apparatus including a mating
structure. The
apparatus also includes a datum. The datum has a first portion configured to
interface
with a work-piece having a critical surfaCe associated with a fit-and-finish
surface. The
datum also has a second portion interfaced with the mating structure. The
datum is
= 4
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=
= adjusted in such a way that the datum facilitates placement of the
critical surface within
acceptable tolerance to the fit-and-finish surface once (A) the datum is
placed between
= the work-piece and the mating structure, and (B) the work-piece is
installed to the mating
= = structure.
=
100020] In order to Mitigate the above, at least in part, in accordance with
an aspect of my
work, I (the inventor) have developed a method for use with a work-piece. The
work- =
=
=
== piece has a critical surface associated with a fit-and-finish
surface, and with a mating
structure. The method includes interfacing a first portion of a datum with the
work-piece.
= The method also includes interfacing a second portion of the datum
with the mating =
structure. The method also includes adjusting the datum in such a way that the
datum
facilitates placement of the critical surface within acceptable tolerance to
the fit-and-
= = finish surface once (A) the datum is placed between the work-piece and
the mating
structure, and (B) the work-piece is installed to the mating structure.
=
[00021] In order to mitigate the above, at least in part, in accordance with
an aspect of my
work, I (the inventor) have developed a method for installing a work-piece to
a mating
structure. The method includes adjusting a datum of the work-piece in such a
way that the
. = datum, once so adjusted, provides a datum feature within
acceptable tolerance. The
datum feature is positionable against a datum interface of the mating
structure in.such a
= way that the datum interface is set apart from a fit-and-finish surface
and from a critical
surface of the work-piece within acceptable tolerance once the datum feature
is so
positioned against the datum interface. The datum feature and the datum
interface
cooperate With each other in such a way that once the work-piece is installed
to the
mating structure, a critical surface of the work-piece is within acceptable
tolerance
= relative to a fit-and-finish surface associated with the critical
surface.
=
= [00022] In order to mitigate the above, at least in part, in accordance
with another aspect
of my work, I (the inventor) have developed a method for installing a work-
piece to a
mating structure. The method includes positioning, within acceptable
tolerance, a critical
=
HON-MD/ODA =
CA 02803709 2013-01-25
= =
surface of the work-piece against a fit-and-finish surface of a nesting
fixture in such a
=
=
= way that the critical surface is acceptably oriented relative to the fit-
and-finish surface
once so positioned. The method further includes adjusting, once the critical
surface is
positioned and acceptably oriented relative to the fit-and-finish surface, a
datum of the
work-piece in such a way that the datum, once so adjusted, provides a datum
feature
within acceptable tolerance. The method includes positioning the datum feature
against a
datum interface of the mating structure in such a way that the datum interface
is set apart
from the fit-and-finish surface and from the critical surface within
acceptable tolerance =
once the datum feature is so positioned against the datum interface. The datum
feature
and the datum interface cooperate with each other in such a way that once the
work-piece .
is installed to the mating structure, a critical surface of the work-piece is
within
= acceptable tolerance relative to a fit-and-finish surface associated with
the critical
surface.
=
[000231 In order to mitigate the above, at least in part, in accordance with
another aspect
of my work, I (the inventor) have developed an apparatus. The apparatus
includes a
mating structure and a work-piece. The mating structure has a datum interface.
The work-
piece has a critical surface and a datum adjusted in such a way that the
datum, once so
adjusted, provides a datum feature Within acceptable tolerance. The datum
feature is
positionable against the datum interface of the mating structure in such a way
that the
datum interface is set apart from a fit-and-finish surface and from the
critical surface
within acceptable tolerance once the datum feature is so positioned against
the datum .
interface. The datum feature and the datum interface cooperate with each other
in such a
way that once the work-piece is installed to the mating structure, a critical
surface of the
=
work-piece is within acceptable tolerance relative to a fit-and-finish surface
associated
with the critical surface.
=
=
[00024] in order to mitigate the above, at least in part, in accordance with
another aspect
of my Work, I (the inventor) have developed an apparatus for use with a mating
structure =
having a datum interface. The apparatus includes a work-piece having a
critical surface
6
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CA 02803709 2013-01-25
'
and a datum. The dattun is adjusted in such a way= that the datum, once so
adjusted,
provides a datum feature within acceptable tolerance. The datum feature is
positionable
against the datum interface of the mating structure in such a way that the
datum interface
is set apart from a fit-and-finish surface and from the critical surface
'within acceptable
= tolerance once the datum feature is so positioned against the datum
interface. The datum
feature and the datum interface cooperate with each other in such a way that
once the
= work-piece is installed to the mating structure, a critical surface of
the work-piece is
within acceptable tolerance relative to a fit-and-finish surface associated
with the critical
surface.
=
[00025] In order to mitigate the above, at least in part, in accordance with
another aspect
of my work, I (the inventor) have developed an apparatus for use with a mating
structure
= having a datum interface and with a work-piece having a critical surface.
The apparatus
includes a datum. The datum is configured to be attached to the work-piece so
as to
extend from the work-piece. The dattun is also configured to be adjusted in
such a way
= that the datum, once so adjusted, provides a datum feature within
acceptable tolerance.
The datum feature is positionable against the datum interface of the mating
structure in
such a way that the datum interface is set apart from a fit-and-finish surface
and from the
critical surface within acceptable tolerance once the datum feature is so
positioned
against the datum interface. The datum feature and the datum interface
cooperate with
=
each other in such a way that once the work-piece is installed to the mating
structure, a
critical surface of the work-piece is within acceptable tolerance relative to
a fit-and-finish
= surface associated with the critical surface.
[00026] In order to mitigate the above, at least in part, in accordance with
another aspect
of my work, I (the inventor) have developed an apparatus including a mating
structure
and a work-piece. The mating structure has a datum interface. The work-piece
has a "
critical surface and a datum. The critical surface is positionable, within
acceptable
"tolerance, against a fit-and-finish surface of a nesting fixture in such a
way that the
critical surface is acceptably oriented relative to the fit-and-finish surface
once so
7
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positioned. The datum has a datum feature. The datum is adjustable, once the
critical
surface is positioned and acceptably oriented relative to the fit-and-finish
surface, in such
a way that the datum, once so adjusted, provides the datum feature within
acceptable
tolerance. The datum feature is positioned against the datum interface of the
mating
structure in such a way that the datum interface is set apart from the fit-and-
finish surface
and from the ethical surface within acceptable tolerance once the datum
feature is so
positioned against the datwn interface. The datum feature and the datum
interface
cooperate with each other in such a way that once the work-piece is installed
to the
mating structure, a critical surface of the work-piece is within acceptable
tolerance
relative to a fit-and-finish surface associated with the critical surface.
[00027] In order to mitigate the above, at least in part, in accordance with
another aspect
of my work, I (the inventor) have developed an apparatus for use with a mating
structure
having a datum interface. The apparatus includes a work-piece. The work-piece
has a
critical surface and a datum. The critical surface is positionable, within
acceptable
tolerance, against a fit-and-finish surface of a nesting fixture in such a way
that the
critical surface is acceptably oriented relative to the fit-and-finish surface
once so
positioned. The datum has a datum feature. The datum is adjustable, once the
critical
surface is positioned and acceptably oriented relative to the fit-and-finish
surface, in such
a way that the datum, once so adjusted, provides the datum feature within
acceptable
tolerance. The datum feature is positioned against the datum interface of thc
mating
structure in such a way that the datum interface is set apart from the fit-and-
finish surface
and from the critical surface within acceptable tolerance once the datum
feature is so
positioned against the datum interface. The datum feature and the datum
interface
= cooperate with each other in such a way that once the work-piece is
installed to the
mating structure, a critical surface of the work-piece is within acceptable
tolerance
relative to a fit-and-finish surface associated with the critical surface.
[00028] In order to mitigate the above, at least in part, in accordance with
another aspect
of my work, I (the inventor) have developed an apparatus for use with a mating
structure
8
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CA 02803709 2013-01-25
having a datum interface, and for use with a work-piece having a critical
surface
positionable, within acceptable tolerance, against a fit-and-finish surface of
a nesting
fixture in such= a way that the critical surface is acceptably oriented
relative to the fit-and-
= finish surface once so positioned. The apparatus includes a datum. The
datum is
configured to be attached to the work-piece so as to extend from the work-
piece. The
= datum has a datum feature. The datum is adjustable, once the critical
surface is positioned
and acceptably oriented relative to the fit-and-finish surface, in such a way
that the
datum, once so adjusted, provides the datum feature within acceptable
tolerance. The
datum feature is positioned against the datum interface of the mating
structure in such a
way that the datum interface is set apart from the fit-and-finish surface and
from the
=critical surface within acceptable tolerance once the datum feature is so
positioned
against the datum interface. The datum feature and the datum interface
cooperate with
each other in such a way that once the work-piece is installed to the mating
structure, a
critical surface of the work-piece is within acceptable tolerance relative to
a fit-and-finish
surface associated with the critical surface.
[00029] In order to mitigate the above, at least in part, in accordance with
another aspect
of rny work, I (the inventor) have developed an apparatus for use with a
mating structure,
and with a work-piece having a critical surface and having the datum
interface. The
apparatus includes the datum. The datum is configured to be attached to the
mating
= structure so as to extend from the mating structure. The datum is also
configured to be
adjusted in such a way that the datum, once so adjusted, provides a datum
feature within
acceptable tolerance. The datum feature is positionable against the datum
interface of the
work-piece in such a way that the datum interface is set apart from a fit-and-
finish
surface and from the critical surface within acceptable tolerance once the
datum feature is
so positioned against the datum interface. The datum feature and the datum
interface
= cooperate with each other in such a way that once the work-piece is
installed to the
mating structure, a critical surface of the work-piece is within acceptable
tolerance
relative to a fit-and-finish surface associated with the critical surface.
9
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mating structure with a corresponding fit-and-finish surface, and the mating
structure is
not properly positioned relative to the corresponding fit-and-fmish surface,
and the
mating structure cannot be repositioned and is fixedly connected to a
surrounding
environment, and the mating structure is positioned relative to the
corresponding fit-and-
finish surface in such a way that the mating structure has unacceptable
tolerance which
cannot be changed and must be accepted as is without further amendments to the
mating
structure relative to the corresponding fit-and-finish surface, and (B)
adjusting the datum
in such a way as to maintain the relationship between the fit-and-finish
surface of the
work-piece relative to the corresponding fit-and-finish surface of the mating
structure.
[00031] In order to mitigate the above, at least in part, in accordance with
other aspects of
my work, I (the inventor) have developed and provided other aspects as
provided in the
claims.
[00032] In another aspect, there is provided an apparatus, comprising a work-
piece having
a critical surface associated with a fit-and-finish surface; a mating
structure; and a datum
having: a first portion interfaced with the work-piece; and a second portion
interfaced
with the mating structure; wherein the datum is adapted by melting for
adjustment in
such a way that the datum facilitates placement of the critical surface within
acceptable
tolerance to the fit-and-finish surface once the datum is placed between the
work-piece
and the mating structure, and the work-piece is installed to the mating
structure.
[00033] In another aspect, there is provided an apparatus, comprising: a datum
having: a
first portion configured to interface with a work-piece having a critical
surface associated
with a fit-and-finish surface; a second portion configured to interface with a
mating
structure and having an unadjusted width; wherein, the second portion is
adjusted to a
width greater than the unadjusted width in such a way that the datum
facilitates
placement of -the critical surface within acceptable tolerance to the fit-and-
finish surface
once the datum is placed between the work-piece and the mating structure, and
the work-
piece is installed to the mating structure.
=r").1 tidil.frnA
=.=
CA 02803709 2015-04-02
[00034] In another aspect, there is provided an apparatus, comprising: a work-
piece
having a critical surface associated with a fit-and-finish surface; and a
datum having: a
first portion being interfaced with the work-piece; a second portion
configured to
interface with a mating structure and having an unadjusted width; wherein the
datum is
adapted by melting the second portion to a width greater than the unadjusted
width for
adjustment in such a way that the datum facilitates placement of the critical
surface
within acceptable tolerance to the fit-and-finish surface once the datum is
placed between
the work-piece and the mating structure, and the work-piece is installed to
the mating
structure.
[00035] ha another aspect, there is provided an apparatus, comprising: a
mating structure;
and a datum having: a first portion configured to interface with a work-piece
having a
critical surface being associated with a fit-and-finish surface; and a second
portion being
interfaced with the mating structure; wherein the datum is adapted by melting
for
adjustment in such a way that the datum facilitates placement of the critical
surface
within acceptable tolerance to the fit-and-finish surface once the datum is
placed between
the work-piece and the mating structure, and the work-piece is installed to
the mating
structure.
[00036] In another aspect, there is provided a method for use with a work-
piece having a
critical surface being associated with a fit-and-finish surface, and with a
mating structure,
the method comprising: interfacing a first portion of a datum with the work-
piece;
interfacing a second portion of the datum with the mating structure; and
adjusting the
datum by melting in such a way that the daturn facilitates placement of the
critical surface
within acceptable tolerance to the fit-and-finish surface once the datum is
placed between
the work-piece and the mating structure, and the work-piece is installed to
the mating
structure,
[00037] Other aspects and features of the non-limiting embodiments may now
become
apparent to those skilled in the art upon review of the following detailed
description of
the non-limiting embodiments vvith the accompanying drawings,
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[00038] BRIEF DESCRIPTION OF DRAWINGS
[00039] The non-limiting embodiments may be tnore fully appreciated by
reference to the
following detailed description of the non-limiting embodiments when taken in
conjunction with the accompanying drawings, in which:
[00040] FIGS. IA and 1B depict a perspective view of an example of a work-
piece;
[00041] FIG. 2 depicts a schematic representation of the work-piece of FIGS.
1A and 1B;
[00042] FIGS. 3 to 13 depict schematic representations of various states of
installation of a
mating structure to the work-piece of FIG. 2; and
[00043] FIGS. 14A, 14B, 14C, 15A, 15B, 15C, 16A, 16B, 16C depict example
representations of adjusting a datum of the work-piece of FIG. 8.
[00044] The drawings are not necessarily to scale and may be illustrated by
phantom lines,
diagrammatic representations and fragmentary views. In certain instances,
details not
necessary for an understanding of the embodiments (and/or details that render
other
details difficult to perceive) may have been omitted.
[00045] DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
12
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CA 02803709 2015-04-02
[00046] The following detailed description is merely exemplary in nature and
is not
intended to limit the described embodiments or the application and uses of the
described
embodiments. As used herein, the word "exemplary" or "illustrative" means
"serving as
an example, instance, or illustration." Any implementation described herein as
"exemplary" or "illustrative" is not necessarily to be construed as preferred
or
advantageous over other implementations. All of the implementations described
below
are exemplary implementations provided to enable persons skilled in the art to
make or
use the embodiments of the disclosure and are not intended to limit the scope
of the
disclosure, which is defined by the claims. For purposes of description
herein, the terms
"upper," "lower," "left," "rear," "right," "front," "vertical.," "horizontal,"
and derivatives
thereof shall relate to the examples as oriented in the drawings. Furthermore,
there is no
intention to be bound by any expressed or implied theory presented in the
preceding
technical field, background, brief summary or the following detailed
description. It is also
to be understood that the specific devices and processes illustrated in the
attached
drawings, and described in the following specification, are simply exemplary
embodiments (examples), aspects and/or concepts defined in the appended
claims.
Hence, specific dimensions and other physical characteristics relating to the
embodiments
disclosed herein are not to be considered as limiting, unless the claims
expressly state
otherwise.
[00047] FIGS. IA and 1B depict the perspective view of the example of the work-
piece
102. FIGS. IA and 1B depict the work-piece 102 ttninstalled (yet to be
installed to a
mating structure).
[00048] On the one hand, FIG. IA depicts a front view that is viewed by a
person for the
case where the work-piece 102 is installed to a mating structure (not depieted
in FIG.
1A). The work-piece 102 provides or includes a critical surface 108 that is
viewed by a
person once the work-piece 102 is installed to the mating structure. By way of
example,
the work-piece 102 includes a headlamp assembly, also called a headlamp module
that is
installable to a vehicle (car and/or truck). Thc work-piece 102 includes a
critical surface
13
CA 02803709 2015-04-02
108, such as a lens surface of a light fixture. The work-piece 102 may include
an interior
component that is installable in an interior passenger cabin of a vehicle such
as a car or
truck. The work-piece 102 includes a structure that is viewed by a person once
installed
to the mating structure. The critical surface 108 is a surface of the work-
piece 102 that
determines the appropriate work-holder design.
[00049] On the other hand, FIG. 1B depicts a back view that is not normally
seen by a
person once the work-piece 102 is installed to the mating structure (not
depicted in FIG.
1B). The work-piece 102 provides, for example, three instances of a datum 104
configured to be interfaced to the mating structure. The datum 104 may include
a datum
structure for each of T, B, H (the x-axis, the y-axis, the z-axis). The datum
104 may be
called a "datum reference". The datum 104 is used for geometric dimensioning
and
tolerancing (GD&T). Each instance of the datum 104 provides surfaces that
respectively
abut respective surfaces of the mating structure; for example, the instances
of the datum
104 are aligned along a respective one of the x-axis, the y-axis, and the z-
axis.
[00050] In GD&T, the datum reference frames may be 3D (three dimensional).
Datum
reference frames may be used as part of a feature control frame to show where
a
measurement is taken from. A datum reference frame may be made up of three
planes.
For example, the three planes may be one "face side" and two "datum edges".
These three
planes are marked A, B and C, where A is the face side, B is the first datum
edge, and C
is the second datum edge. In this case, the datum reference frame is A/B/C.
A/B/C is
shown at the end of the feature control frame to show from where the
measurement is
taken. Reference is made to the ASME standard Y14.5M-1994 for more examples
and
material modifiers. The engineer may select A/B/C based on the dimensional
function of
the part. The datum may be functional per the ASME standard. A part, such as
the work-
piece 102, may be required to fit with other parts (such as a mating
structure). The
functional datum may be chosen (selected) based on how the part attaches. The
functional
datum do not have to be used to manufacture the part. The manufacturing datum
may be
different than the functional datum to reduce cost, improve process speed and
14
CA 02803709 2015-04-02
repeatability (if so required). A tolerance analysis may be needed in some
cases to
convert between the functional datum and the manufacturing datum. Computer
software
may be used for dimensional analysis.
[00051] FIG. 2 depicts the schematic representation of the work-piece 102 of
FIGS. 1A
and 1B.
[00052] FIGS. 2 and 3 depict the schematic representations of the installation
of the work-
piece 102 to the mating structure 202 of FIG. 3.
[00053] The unadjusted datum 105 is depicted. The unadjusted datum 105 will be
adjusted
(modified, etc.) so as to form the datum 104 as depicted in FIGS. 1A, 1B, 7,
8, and 9 (for
example).
[00054] The work-piece 102 includes the critical surface 108 oriented in a
direction, and
also includes at least one or more instances of the unadjusted datum 105 that
is set apart
from the critical surface 108. It will be appreciated that the unadjusted
datum 105 may be
configured for attachment to the work-piece 102, or the unadjusted datum 105
extends
from the work-piece 102. For example, for the case where the work-piece 102
includes a
molded article or an injection-molded body, the unadjusted datum 105 extends
from the
body of the work-piece 102 since the unadjusted datum 105 is formed (molded)
to the
body. However, it will be appreciated that the unadjusted datum 105 may be
attached to
the work-piece 102 if so required for the case where the unadjusted datum 105
is not
formed to the work-piece 102.
[00055] FIG. 3 depicts the schematic example of a combination of the work-
piece 102
installed to the mating structure 202, with the unadjusted datum 105
positioned between
the work-piece 102 and the mating structure 202. By way of example, the
unadjusted
datum 105 extends from the work-piece 102, and abuts a datum interface 204 of
the
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CA 02803709 2015-04-02
mating structure 202. It will be appreciated that the opposite relationship
may exist (not
depicted) in which the unadjusted datum 105 extends from the mating structure
202, and
the work-piece 102 provides the datum interface 204. The unadjusted datum 105
may
include an x-axis datum for the x-axis, a y-axis datum for the y-axis, and a z-
axis datum
for the z-axis. For the sake of simplification, a single instance of the
unadjusted datum
105 is depicted. The unadjusted datum 105 is configured in such a way that the
unadjusted datum 105 permits the fit-and-finish surface 902 and the critical
surface 108
of the work-piece 102 to be positioned within acceptable tolerance relative to
each other,
[00056] FIG. 3 depicts a case for an ideal condition, in which the
manufacturing and/or
construction of the components of the mating structure 202, of the work-piece
102, and of
the unadjusted datum 105 were accomplished so that the work-piece 102 and the
mating
structure 202, when assembled together, have acceptable accumulated tolerances
(as a
whole). For exatnple, perhaps a combination of molding operations and gluing
operations
were used to manufacture and assemble the mating structure 202 and the work-
piece 102
such that each of the tolerances of the components is acceptable, and the
accumulated
tolerance associated with the assembled components happens to be acceptable as
well so
that in the end, the critical surface 108 matches up with the fit-and-finish
surface 902
within acceptable tolerance. However, this represents the ideal condition in
which the
components may be manufactured and may be assembled within tolerances;
moreover,
this ideal condition is not likely to exist for every day of manufacturing. It
will be
appreciated that manufacturing conditions may change from day to day, and
these
changes may not be controllable. The changing manufacturing conditions may
cause
variations in manufacturing tolerances that may result in components
manufactured
and/or assembled in such a way as to be outside of acceptable tolerances. Some
of these
unacceptable tolerances may be large enough such that the fit-and-finish
surfaces
associated with these out-of tolerance components may become inadvertently out
of
tolerance as well.
[00057] FIGS. 4 to 13 depict the schematic representations of the various
states of
installation of the work-piece 102 to the mating structure 202 of FIG. 4.
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[00058] FIG, 4 depicts the schematic example of a case where the accumulated
tolerances
associated with manufacturing and assembling the components of the work-piece
102 and
the mating structure 202, and/or installing the work-piece 102 to the mating
structure 202
leads to an unacceptable result. The unadjusted datum 105 does not permit the
work-
piece 102 and the mating structure 202 to be assembled in such a way that the
unadjusted
datum 105 fails to permit the fit-and-finish surface 902 and the critical
surface 108 of the
work-piece 102 to be positioned within acceptable tolerance relative to each
other. As
depicted in FIG. 4, the fit-and-finish surface 902 and the critical surface
108 of the work-
piece 102 are not positioned within acceptable tolerance relative to each
other. Perhaps
the individual tolerances of the components are within acceptable limits, and
that the
accumulation of tolerances is not within acceptable limits once the work-piece
102 is
installed to the mating structure 202. The accumulation of tolerances may be
called the
stack-up of variances. As depicted, the critical surface 108 does not fit
within acceptable
tolerance relative to the fit-and-finish surface 902. As depicted, a person
(consumer) may
not be interested in purchasing the complete assembly as depicted because the
critical
surface 108 does not fit within acceptable tolerance relative to the fit-and-
finish surface
902.
[00059] FIG. 5 depicts the schematic example of an initial operation of a
method for
installing the work-piece 102 to the mating structure 202. The unadjusted
datum 105
extends from the work-piece 102. The critical surface 108 of the work-piece
102 is to be
positioned in the fit-and-finish surface 902 that is provided by (defined by)
a nesting
fixture 904. Once the critical surface 108 is positioned next to (proximate
to, adjacent to)
the fit-and-finish surface 902, the work-piece 102 will be clamped
(temporarily fixedly
connected) to the nesting fixture 904.
(00060) FIG. 6 depicts the schematic example in which the critical surface 108
is
positioned next to the fit-and-finish surface 902. The nesting fixture 904
receives the
critical surface 108. The work-piece 102 will be clamped (temporarily fixedly
connected)
17
CA 02803709 2015-04-02
to the nesting fixture 904 so that the fit-and-finish surface 902 and the
critical surface 108
are within acceptable tolerance relative to each other.
[00061] FIG. 7 depicts the schematic example in which a target distance 907 is
used to
identify a potential adjustment may be made to the unadjusted datum 105. The
potential
adjustment to the unadjusted datum 105 is such that once the work-piece 102
and the
mating structure 202 (as depicted in FIG. 9) are installed together, the fit-
and-finish
surface 902 and the critical surface 108 are within acceptable tolerance
relative to each
other. The potential adjustment to the unadjusted datum 105 may include (for
example)
the removal of a sacrificial portion 506 (also called a material) to be
removed from the
unadjusted datum 105. The datum 104 was manufactured as a result of removing
the
sacrificial portion 506 from the unadjusted datum 105. A material-manipulation
tool (not
depicted) may be used to adjust the unadjusted datum 105. The amount of
material to be
removed (adjusted) from the unadjusted datum 105 is enough to permit
acceptable
tolerance between the critical surface 108 and the fit-and-finish surface 902
once the
work-piece 102 is installed to the mating structure 202.
[00062] FIG. 8 depicts the schematic example in which the unadjusted datum 105
is cut
(adjusted) so as to leave behind the datum 104 and the sacrificial portion 506
that is
removed or separated. It will be appreciated that material may be added to the
unadjusted
datum 105 if so required and if so possible in order Co form or manufacture
the datum
104. The datum 104 may be called the adjusted datum. It will be appreciated
that the
datum 104 may include an x-axis datum, a y-axis datum and a z-axis datum. A
single
instance of the datum 104 is depicted for the sake of simplification of
describing the
example.
[00063] In view of FIGS 7 and 8, there is provided (depicted) a method. The
method is for
installing the work-piece 102 to the mating structure 202. The method includes
an
operation (A). The operation (A) includes adjusting the datum 104 of the work-
piece 102
in such a way that the datum 104, once so adjusted, provides a datum feature
106. The
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datum feature 106 is depicted in FIG. 8 as a surface feature. The datum
feature 106 is
provided within acceptable tolerance. The datum feature 106 is positionable
against the
datum interface 204 ¨which is depicted in FIG. 9¨ of the mating structure 202
in such a
way that the datum interface 204 is set apart from the fit-and-finish surface
902 and from
the critical surface 108 of the work-piece 102 within acceptable tolerance
once the datum
feature 106 is so positioned against the datum interface 204. The datum
feature 106 and
the datum interface 204 cooperate with each other in such a way that once the
work-piece
102 is installed to the mating structure 202, a critical stuface 108 of the
work-piece 102 is
within acceptable tolerance relative to a fit-and-finish surface 902
associated with the
critical surface 108.
[00064] In view of FIGS. 7 and 8 (in accordance with an option), there is
provided the
apparatus 100 that includes a combination of the mating structure 202 and the
work-piece
102. The mating structure 202 has a datum interface 204. The work-piece 102
has a
critical surface 108 and a datum 104. The datum 104 is adjusted in such a way
that the
datum 104, once so adjusted, provides the datum feature 106 within acceptable
tolerance.
The datum feature 106 is positionable against the datum interface 204 of the
mating
structure 202 in such a way that the datum interface 204 is set apart from a
fit-and-finish
surface 902 and from the critical surface 108 within acceptable tolerance once
the datum
feature 106 is so positioned against the datum interface 204.
[00065] In view of FIGS. 7 and 8 (in accordance with another option), there is
provided
the apparatus 100 for use with the mating structure 202 that has a datum
interface 204.
The apparatus 100 includes the work-piece 102 without the mating structure
202. The
work-piece 102 has the combination of the critical surface 108 and the datum
104.
[00066] In view of FIGS. 7 and 8 (in accordance with yet another option),
there is
provided the apparatus 100 for use with the mating structure 202 that has the
datum
interface 204. The apparatus 100 is also for use with the work-piece 102 that
has a critical
surface 108. The apparatus 100 includes a datum 104 and does not include the
mating
19
CA 02803709 2015-04-02
structure 202 and the work-piece 102; that is, the datum 104 is provided (in
this case) as a
separate item to be combined with the work-piece 102.
[00067] In view of FIGS. 7 and 8, it will be appreciated that in general terms
in
accordance with a general example, the apparatus 100 includes the combination
of the
work-piece 102, the mating structure 202 and the datum 104. The datum 104 and
the first
portion 101 are interfaced with the work-piece 102. The datum 104 also has a
second
portion 103 ¨ as depicted in FIG. 9 -- interfaced with the mating structure
202. The datum
104 is adjusted in such a way that the datum 104 facilitates placement of the
critical
surface 108 within acceptable tolerance to the fit-and-finish surface 902 once
the datum
104 is placed between the work-piece 102 and the mating structure 202, and the
work-
piece 102 is installed to the mating structure 202.
[00068] In view of the first general example, it will be appreciated that
another option is
such that the apparatus 100 includes the datum 104 without the combination of
the work-
piece 102 and the mating structure 202.
[00069] In view of the first general example, it will be appreciated that
another option is
such that the apparatus 100 includes the combination of the datum 104 and the
work-
piece 102, without the mating structure 202.
[00070] In view of the first general example, it will be appreciated that
another option is
such that the apparatus 100 includes the combination of the datum 104 and the
mating
structure 202 without the work-piece 102.
[00071] In view of the first general example, there is provided a method for
use with the
work-piece 102 and with the mating structure 202. The method includes the
combination
of: operation (A), operation (B), and operation (C). Operation (A) includes
interfacing a
first portion 101 of a datum 104 with the work-piece 102. Operation (B)
includes
interfacing a second portion 103 ¨which is depicted in FIG. 9¨ of the datum
104 with the
CA 02803709 2015-04-02
mating structure 202. Operation (C) includes adjusting the datum 104 in such a
way that
the datum 104 facilitates placement of the critical surface 108 within
acceptable tolerance
to the fit-and-finish surface 902 once (i) the datum 104 is placed between the
work-piece
102 and the mating structure 202, and (ii) the work-piece 102 is installed to
the mating
structure 202.
[00072] According to a variation, the work-piece 102 includes a vehicle
assembly, such as
a headlight assembly for example, and the mating structure 202 includes a
vehicle (car or
truck). According to a specific variation, the datum 104 includes a plastic
material
configured to be adjusted. It will be appreciated that the datum 104 may
include any
adjustable material (metal, plastic, etc).
[00073] FIG. 9 depicts the schematic example in which the work-piece 102 is
installed to
the mating structure 202 with the datum 104 placed between the work-piece 102
and the
mating structure 202. The datum 104 is configured to reduce (at least in part)
errors
(manufacturing errors) associated with stack-up errors (manufacturing
components and/or
assembling component on component for example) that leads to the critical
surface 108
to not be within acceptable tolerance to the fit-and-finish surface 902.
[00074] In view of FIGS. 6, 7, 8, and 9, there is provided a method. The
method is for
installing the work-piece 102 to the mating structure 202. The method includes
a
combination of operation (A), operation (B) and operation (C). Operation (A)
is
associated with FIG. 6. Operation (A) includes positioning, within acceptable
tolerance,
the critical surface 108 of the work-piece 102 against the fit-and-finish
surface 902 of the
nesting fixture 904 in such a way that the critical surface 108 is acceptably
oriented
relative to the fit-and-finish surface 902 once so positioned. Operation (B)
is associated
with FIGS. 7 and 8. Operation (B) includes adjusting (once the critical
surface 108 is
positioned and acceptably oriented relative to the fit-and-finish surface 902)
the datum
104 of the work-piece 102 in such a way that the datum 104, once so adjusted,
provides
within acceptable tolerance. The datum feature 106 is depicted in FIG. 8.
Operation (C) is
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associated with FIG. 9. Operation (C) includes positioning the datum feature
106 against
the datum interface 204 of the mating structure 202 in such a way that the
datum interface
204 is set apart from the fit-and-finish surface 902 and from the critical
surface 108
within acceptable tolerance once the datum feature 106 is so positioned
against the datum
interface 204. The datum feature 106 and the datum interface 204 cooperate
with each
other in such a way that once the work-piece 102 is installed to the mating
structure 202,
a critical surface 108 of the work-piece 102 is within acceptable tolerance
relative to a fit-
and-finish surface 902 associated with the critical surface 108.
[00075] In view of FIGS. 6, 7, 8, and 9, there is provided the apparatus 100
in which the
apparatus 100 includes a combination of the mating structure 202 and the work-
piece
102. The mating structure 202 has a datum interface 204. The work-piece 102
has the
combination of the critical surface 108 and the datum 104. The critical
surface 108 is
positionable, within acceptable tolerance, against the fit-and-finish surface
902 of the
nesting fixture 904 in such a way that the critical surface 108 is acceptably
oriented
relative to the fit-and-finish surface 902 once so positioned. The datum 104
has a datum
feature 106. The datum 104 is adjustable, once the critical surface 108 is
positioned and
acceptably oriented relative to the fit-and-finish surface 902, in such a way
that the datum
104, once so adjusted, provides the datum feature 106 within acceptable
tolerance. The
datum feature 106 is positioned against the datum interface 204 of the mating
structure
202 in such a way that the datum interface 204 is set apart from the fit-and-
finish surface
902 and from the critical surface 108 within acceptable tolerance once the
datusrA feature
106 is so positioned against the datum interface 204.
[00076] In view of FIGS. 6, 7, 8, and 9, there is provided the apparatus 100
for use with
the mating structure 202 having the datum interface 204. The apparatus 100
includes the
work-piece 102, and does not include the mating structure 202.
[00077] In view of FIGS, 6, 7, 8, and 9, there is provided the apparatus 100
for use with
the mating structure 202 having the datum interface 204, and for use with the
work-piece
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102 having the critical surface 108. The apparatus 100 includes the datum 104,
and does
not include the work-piece 102 and the mating structure 202.
[00078] In view of FIGS. 6, 7, 8, and 9, there is provided the apparatus 100
for use with
the mating structure 202 and with the work-piece 102. The work-piece 102 has
the
critical surface 108 and has the datum interface 204. The apparatus 100
includes the
datum 104 without the mating structure 202 and without the work-piece 102, The
datum
104 is configured to be attached to the mating structure 202 so as to extend
from the
mating structure 202. The datum 104 is also configured to be adjusted in such
a way that
the datum 104, once so adjusted, provides a datum feature 106 within
acceptable
tolerance, The datum feature 106 is positionable against the datum interface
204 of the
work-piece 102 in such a way that the datum interface 204 is set apart from a
fit-and-
finish surface 902 and from the critical surface 108 within acceptable
tolerance once the
datum feature 106 is so positioned against the datum interface 204.
[00079] FIG. 10 depicts the schematic example in which the mating structure
202 is
associated with a corresponding fit-and-finish surface 903 along with the fit-
and-finish
surface 902 of the work-piece 102. The example of FIG. 10 is such that the
mating
structure 202 is properly positioned relative to the corresponding fit-and-
finish surface
903, and the alignment or placement of the fit-and-finish surface 902 and the
corresponding fit-and-finish surface 903 are within tolerance relative to each
other. FIG.
depicts an ideal condition.
[00080] FIG. 11 depicts the example in which the mating structure 202 is not
properly
positioned relative to the corresponding fit-and-finish surface 903, and the
mating
structure 202 cannot be moved or repositioned because the mating structure 202
is
fixedly connected to its surrounding environment of components. The mating
structure
202 is pushed forwardly toward (positioned relative to) the corresponding fit-
and-finish
surface 903. For this case, the mating structure 202 has unacceptable
tolerances that
cannot be changed and must be accepted as is without further amendments to the
mating
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structure 202 relative to the corresponding fit-and-finish surface 903.
However, it may be
desirable to maintain and/or adjust the relationship between the fit-and-
finish surface 902
of the work-piece 102 relative to the corresponding fit-and-finish surface 903
of the
mating structure 202.
[00081] FIG. 12 depicts the schematic example in which the requirement is to
maintain the
relationship between the fit-and-finish surface 902 of the work-piece 102
relative to the
corresponding fit-and-finish surface 903 of the mating structure 202. The
datum 104 was
adjusted (such as, by having material removed from an unadjusted datum 105) in
such a
way as to maintain the relationship between the fit-and-finish surface 902 of
the work-
piece 102 relative to the corresponding fit-and-finish surface 903 of the
mating structure
202.
[000821 For the case (not depicted) where the requirement is to change the
relationship
between the fit-and-finish surface 902 relative to the corresponding fit-and-
finish surface
903, the datum 104 is adjusted in such a way as to facilitate (permit) the
required change
in the relationship between the fit-and-finish surface 902 relative to the
corresponding fit-
and-finish surface 903, as may be needed.
[00083) FIG. 13 depicts the schematic example in which the mating structure
202 is
positioned further away from the corresponding fit-and-finish surface 903.
Once again,
the mating structure 202 cannot be relocated or repositioned since it is now
fixedly
connected to its surrounding environment. The datum 104 was adjusted (such as,
by
having material removed from an unadjusted datum 105) in such a way as to
maintain the
relationship between the fit-and-finish surface 902 of the work-piece 102
relative to the
corresponding fit-and-finish surface 903 of the mating structure 202.
[00084] FIGS. 14A, 14B, 14C, 15A, 15B, 15C, 16A, 16B, 16C depict example
representations of adjusting the unadjusted datum 105 of the work-piece 102 so
as to
foim the datum 104 of FIG. 8.
24
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[00085] FIG. 14A depicts the schematic example of a tool system 906 configured
to adjust
the instances of the unadjusted datum 105 extending from the work-piece 102.
The work-
piece 102 includes a plastic material, and the tool system 906 includes a hot
plate. The
tool system 906 wilt be moved so as to abut against the unadjusted datum 105,
causing
the unadjusted datum 105 to be adjusted or re-melted at least in part.
[00086] FIG. 14B depicts the schematic example of the tool system 906
positioned in such
a way that a melted portion 107 is formed and extends from the datum 104 (as
adjusted to
an adjusted width greater than the unadjusted width as seen in FIG 14A). Once
so formed
or adjusted, the tool system 906 is retracted away from the work-piece 102.
[00087] FIG. 14C depicts the schematic example showing the datum feature 106
of the
datum 104 (as adjusted) extending from the work-piece 102, and the melted
portion 107
surrounds the datum feature 106. The datum feature 106 will be placed against
the mating
structure 202 of FIG. 8 once the work-piece 102 is installed to the mating
structure 202.
The datum feature 106 includes a flat planar surface.
[00088] FIG. 15A depicts the schematic example of the tool system 906
configured in
such a way so as to adjust the unadjusted datum 105 extending from the work-
piece 102.
The work-piece 102 includes a plastic material, and the tool system 906
includes the hot
plate. The tool system 906 will be moved so as to abut against the unadjusted
datum 105,
thus causing the unadjusted datum 105 to be adjusted or re-melted at least in
part,
resulting in at least a portion remaining unadjusted after the datum is
adjusted.
[00089] FIG. 15B depicts the schematic example of the tool system 906
positioned in such
a way that a melted portion 107 is formed and extends from the datum 104. Once
so
formed or adjusted, the tool system 906 is retracted away from the work-piece
102.
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[00090] FIG. 15C depicts the schematic example showing the datum feature 106
of the
datum 104 (as adjusted) extending from the work-piece 102, and the melted
portion 107
surrounds the datum feature 106. The datum feature 106 will be placed against
the mating
structure 202 of FIG. 8 once the work-piece 102 is installed to the mating
structure 202.
The datum feature 106 includes an outer surface of a cylindrical post
extending from the
datum 104 and also includes a fiat planar =face surrounding the outer surface
of the
cylindrical post.
[00091] FIG. 16A depicts the schematic example of the tool system 906
configured in
such a way so as to adjust the unadjusted datum 105 extending from the work-
piece 102.
The work-piece 102 includes a plastic materia], and the tool system 906
includes a drill
device. The tool system 906 will be moved so as to abut against the unadjusted
datum
105, and then drill, at least in part, into the unadjusted datum 105.
[00092] FIG. 16B depicts the schematic example of the tool system 906
positioned in such
a way that the drill device has drilled into the datum 104. Once so formed or
adjusted, the
tool system 906 is retracted away from the work-piece 102.
[00093] FIG. 16C depicts the schematic example showing the datum feature 106
of the
datum 104 (as adjusted) extending from the work-piece 102. The datum feature
106
includes an inner facing surface positioned in a hole defined by the datum
104, wherein
an inner portion of the datum 104 (at the data feature 106) has a length which
is less than
the unadjusted length of the datum 104.
[00094] ADDITIONAL DESCRIPTION
[00095) To make a headlight assembly of a vehicle, a housing and lens are
separately
molded. The datum may be positioned on the molded housing, and the housing and
lens
are glued together. Processes stack up the molding variation of the housing
and the lens
with the variation associated with (for example) gluing and assembly. The sum
of these
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variances (or tolerances) will not allow for relatively small design gaps (for
example) of
1.5 mm (millimeters) or more (as may be permitted or tolerated).
[00096] Plastic parts, or the work-piece 102, and assemblies, due to molding
and assembly
process variations, may not be able to meet the required tolerances.
Initially, the work-
piece 102 may be molded or assembled. The work-piece 102 may then be located
and
clamped to the fit-and-finish surface 902. A material adjustment tool (such as
a hot plate,
broach, cutter, robot-controlled tool, or other tooling) is used to adjust a
datum. The
adjusted datum helps to reduce variation and creates a direct and adjustable
link between
the controlled surfaces. The locating and nesting of the work-piece may be
(for example)
less than 0.2 mm (millimeters), and the material manipulation (adjustment)
tool may be
less than 0.05 mm (for example). The total stack-up may then be less than 0.3
mm of
variation. The stacked-up variations may be reduced by creating (forming,
manufacturing) the datum off of the fit-and-finish surface 902. Adjustment of
the datum
also allows for improved adjustment or tuning of dimensions associated with
the work-
piece and/or mating structure. This approach may include locating one side of
a
dimension of a critical surface 108 with the fit-and-finish surface 902, and
then forming
(adjusting) the datum with tooling. The distance between the datum and the fit
and finish
surface is too far as a result of errors due to stack up (for example, molding
variations
and/or gluing variations).
[00097] After the part is assembled and the critical surface 108 is located, a
hot plate tool
(a broach, cutter or some other tooling) is used to form the final (adjusted)
datum. Extra
material and relief areas for the displaced material may be required in the
original molded
part. The tooling may cut away the extra material or press the material into
relief areas,
leaving the newly formed (adjusted) datum, The hot plate tool may include a
non-stick
surface or coating so that the thermal range may be determined by material
being
displaced.
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[00098] The above describes ways in which to produce (manufacture) work-piece
102
such as plastic parts, having a better fit by locating the datum directly from
the fit-and-
finish surface 902 of the work-piece 102. The work-piece 102 may include
several
individual parts (e.g., housing and lens). Each of these parts may have
molding variations
that, when stacked up (combined) after assembly, contribute to a less than
desirable fit.
Gluing together of such parts may also contribute to a less than desirable
fit. The datum
for such components are not typically located on the fit-and-finish surface
902. For
example, the datum for a headlamp assembly may be located on a housing.
Initially, the
work-piece 102 is manufactured (such as molding a desired part, etc.). The
work-piece
102 is clamped to an associated assembly/component such as the nesting fixture
904, and
the work-piece 102 is positioned in the nesting fixture 904 such that the fit-
and-finish
surface 902 is properly located. Initial (or unadjusted) datum (e.g., pin
structures) are
formed (on the external part of the housing) relative to the fit-and-finish
surface 902. The
initial datum may include excess plastic material as well as associated relief
areas (for
example). Tooling (such as a hot plate, broach or cutter) is then used to
produce (form,
adjust) the initial datum so as to provide an adjusted datum (within an
acceptable
tolerance); this may be accomplished by (for example) either cutting away
extra material
from the datum pins or pressing it into relief areas, thus leaving a newly
formed
(adjusted) datum (such as a datum surface). The formed datum may be used to
ensure that
the critical surface 108 of the work-piece 102 may be properly located once
the work-
piece 102 is assembled to the mating structure 202, This approach may improve
the
overall fit and finish quality of the work-piece 102 once mated to a mating
structure.
[00099] For example, the process or method may include an operation (A)
includes:
creating a correct part datum (adjusting the datum) by manufacturing the work-
piece 102
(such as molding a desired part). An operation (B) includes subsequently
clamping the
work-piece 102 to an associated fixture (such as the nesting fixture 904) with
the work-
piece 102 positioned in such a way that the critical surface 108 is located
relative to the
fit-and-finish surface 902 within acceptable tolerance. An operation (C)
includes
removing excess material (adjusting the datum) from the unadjusted datum 105
(such as
pins) that extend from the work-piece 102 to leave a newly formed (adjusted)
datum or
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CA 02803709 2015-04-02
datum 104. The newly formed (adjusted) datum reflects an improved positioning
of the
critical surface 108 of the work-piece 102 relative to the fit-and-finish
surface 902 once
the work-piece 102 is installed to the mating structure 202. The above
concepts describe
a way to manufacture the work-piece 102 in such a way that the work-piece 102
has a
better (improved) fit by locating (adjusting) the datum directly from the
critics] surface
108 of the work-piece 102 relative to fit-and-finish surface 902. For example,
a headlamp
assembly includes several individual parts (e.g., housing and lens). Each of
these parts
may have molding variations that, when stacked up (combined) after assembly,
contribute to a less than desirable fit. Gluing together of such parts may
also contribute to
a less than desirable fit. The datum for such components are not typically
located relative
to the fit-and-finish surface 902 associated with the work-piece 102. For
example, the
datum for a headlamp assembly are located on the housing. For the headlight
assembly,
initially the headlight assembly is molded, then the molded part is clamped to
an
associated assembly/component (nest fixture having the fit-and-finish surface
902) with
the molded part positioned such that the critical surface 108 of the work-
piece 102 is
positioned relative to the fit-and-finish surface 902 within acceptable
tolerance. Initial or
unadjusted datum 105 (e.g., pins) is formed relative to the fit-and-finish
surface 902, and
include excess plastic material as well as associated relief areas. Tooling is
then used to
produce (form) datum having improved accuracy (within tolerance) by either
cutting
away extra material from the unadjusted datum 105 (unadjusted pins), or
pressing the
unadjusted datum 105 into relief areas leaving a newly formed (adjusted) datum
104 that
may be used to ensure that the critical surface 108 of the work-piece 102 is
located
relative to the fit-and-finish surface 902 once or when the work-piece 102 is
installed to
the mating structure 202.
[0001001 It will be appreciated that any material adjustment process may be
used to form
the datum, including adding material and/or removing material,
[000101) It may be appreciated that the assemblies and modules described above
may be
connected with each other as may be required to perform desired functions and
tasks that
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CA 02803709 2015-04-02
are within the scope of persons of skill in the art to make such combinations
and
permutations without having to describe each and every one of them in explicit
terms.
There is no particular assemblies, components that are superior to any of the
equivalents
available to the art. There is no particular mode of practicing the disclosed
subject matter
that is superior to others, so long as the functions may be performed. It is
believed that all
the crucial aspects of the disclosed subject matter have been provided in this
document. It
is understood that the scope of the present invention is limited to the scope
provided by
the independent claim(s), and it is also understood that the scope of the
present invention
is not limited to: (i) the dependent claims, (ii) the detailed description of
the non-limiting
embodiments, (iii) the summary, (iv) the abstract, and/or (v) description
provided outside
of this document (that is, outside of the instant application as filed, as
prosecuted; and/or
as granted). It is noted that the foregoing has outlined the non-limiting
embodiments
(examples). The description is made for particular non-limiting embodiments
(examples).
It is understood that the non-limiting embodiments are merely illustrative as
examples.
r k li,Ts% A
