Roller press assembly and method

Abstract

The present invention provides an assembly for securing components of a damper assembly, the assembly comprising a press movable along an axis from a retracted position to an extended position. The assembly includes a plurality of rollers rotatably supported at ends of the press. The rollers have an outer circumferential surface including a middle portion that, in cross-section, is transverse to the axis and extends linearly between an inlet portion and a top portion of the outer circumferential surface.

Description

Background Art

[0001] Dampers are commonly used in conjunction with automotive or other suspension systems to control the movement of the vehicle's wheels relative to the vehicle's body. To control movement, the damper assembly is typically connected between the vehicle's sprung (body) and unsprung (suspension / drivetrain) mass locations. BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Figure 1 is a perspective view of a vehicle having multiple damper assemblies.

[0003] Figure 2 is a cross-section of a component of one of the components in the damper assembly, which includes the rod and valve assembly.

[0004] Figure 3A is a side view of a press with rollers for assembling a damper assembly, the press in a retracted position.

[0005] Figure 3B is a side view of the press in the extended position.

[0006] Figure 4 It is a bottom view of the head unit of the press supporting the rollers.

[0007] Figure 5A is a side view of the valve assembly of the press and damper assembly in the retracted position.

[0008] Figure 5B yes Figure 5A Close-up of a part of.

[0009] Figure 6A is a side view of the valve assembly of the press and damper assembly in the extended position.

[0010] Figure 6B yes Figure 6A Close-up of a part of.

[0011] Figure 7 is a flow chart illustrating a process for assembling a valve assembly of a damper assembly. DETAILED DESCRIPTION

[0012] An assembly for securing components of a damper assembly comprises a press that is movable along an axis from a retracted position to an extended position. The assembly comprises a plurality of rollers rotatably supported at the ends of the press. The rollers have an outer circumferential surface comprising a middle portion that, in cross-section, is transverse to the axis and extends linearly between an inlet portion and a top portion of the outer circumferential surface. The middle portion of the roller forms, for example, a middle portion of a housing. The middle portion reinforces the ends of the housing so that welds (or other fixtures, such as threaded connections) may not be required to secure the ends of the housing.

[0013] refer to Figure 1 , and wherein like numerals represent like elements throughout the several views, the figure shows a vehicle 30 having a plurality of damper assemblies 32. The vehicle 30 may be any suitable type of ground vehicle, for example, a passenger or commercial vehicle such as a car, coupe, truck, sport utility vehicle, forklift, van, minivan, taxi, bus, etc.

[0014] The damper assembly 32 is typically used in conjunction with an automotive suspension system or other suspension system to control the movement of the wheels of the vehicle 30 relative to the body of the vehicle 30. To control the movement, the damper assembly 32 is typically connected between the sprung (body) mass and the unsprung (suspension / drivetrain) mass positions of the vehicle 30. Each damper assembly 32 can be coupled to a coil spring. Each damper assembly 32 is capable of moving from a compressed position to an extended position, and vice versa. The distance between the ends 48 of the damper assembly 32 (i.e., the distance from one end 48 to the other end 48) is less in the compressed position than in the extended position. The coil spring or the like can urge the damper assembly 32 toward the extended position. For example, forces applied to the wheels of the vehicle 30 due to bumps, potholes, etc. can urge the damper assembly 32 toward the compressed position.

[0015] Each damper assembly 32 controls movement of a corresponding wheel by restricting the flow of fluid into, out of, and / or between various chambers of the damper assembly 32 (e.g., into, out of, and / or between a compression chamber and a rebound chamber, between a reserve chamber and a compression chamber and / or rebound chamber, etc.). For example, when the damper assembly 32 moves toward a compressed position or an extended position, the fluid is caused to move by moving a piston within a pressure tube of the damper assembly 32.

[0016] Each damper assembly 32 may include one or more valve assemblies that control fluid flow, for example, through one or more passages 38 connecting the rebound chamber, the compression chamber, and / or the reserve chamber. The valve assembly may include a spring, a relief disc, a flow restriction disc, etc. For example, and with reference to Figure 2, a rod-end valve assembly 34 is shown. The rod-end valve assembly 34 is fixed to the end of a hollow piston rod 36, for example, to control the flow of fluid into and out of a passage 38 of the piston rod 36.

[0017] The rod-end valve assembly 34 includes a housing 40 and a body 42 that encloses other components 44 (e.g., a spring, a valve disc, etc.) therein. The body 42 threadably engages the piston rod 36. The housing 40 may include an outer cylindrical body 46 and an end 48 extending radially inward from the outer cylindrical body 46. The end 48 retains the body 42 within the outer cylindrical body 46, for example, by compressing the components 44 therein between the body 42 and the bottom of the housing 40. The housing 40 defines a wall thickness between, for example, an inner surface 50 of the housing 40, which faces the other components 44 of the rod-end valve assembly 34, and an outer surface 52 of the housing 40, which faces away from the other components 44.

[0018] The housing 40 can include a housing mid-section 54 that extends linearly between the end 48 and the outer cylindrical body 46. The housing mid-section 54 provides increased strength and stiffness to the housing 40, for example relative to the continuous bend connecting the outer cylindrical body 46 and the end 48. The increased strength and stiffness can enable the end 48 to maintain the body 42 in place and provide a compressive preload to the components 44 within the housing 40, for example, without requiring a weld or the like to secure the end 48 to the body 42, such as a threaded connection between the body 42 and the housing 40. The length of the housing mid-section 54 at the outer surface 52 is equal to or greater than the wall thickness. By extending the end 48 from the outer cylindrical body 46 to the housing 40, the housing 40 can be made substantially uniform. Figure 5A and Figure 5B The initial position shown in the figure is bent to Figure 2 、 Figure 6A and Figure 6B The end position shown in , forms the middle portion 72.

[0019] refer to Figures 3A to 6B , shows a press 56 for bending the end 48 of the housing 40 from an initial position to an end position. The press 56 (eg, the head unit 58 at the end 48 of the press 56) is capable of bending the housing 40 from an initial position to an end position along the axis A1. Figure 3A and Figure 5A Move to the retracted position shown in Figure 3B and Figure 6A. The press 56 generates a force along the axis A1. The press 56 may include, for example, a piston and cylinder actuated via hydraulic or pneumatic operation. The press 56 may include, for example, a rack and pinion actuated via an electric motor and a reduction gear. The press 56 may include any other suitable structure for providing a force along the axis A1. The press 56 rotates about the axis A1. For example, the press 56 may include an electric motor, a reduction gear, or any other suitable structure that causes the head unit 58 to rotate about the axis A1 and relative to the body 84 of the press 56. The axis A1 may extend through the center of the head unit 58.

[0020] A plurality of rollers 60 are rotatably supported at the end 48 of the press 56. Each of the rollers 60 may be capable of rotating around a corresponding second axis in the plurality of second axes A2. For example, each of the plurality of rollers 60 may be rotatably supported by the head unit 58 via an axle pin 62 and one or more bearings (or other suitable structures). Each axle pin 62 may extend along a corresponding second axis A2. The second axis A2 is transverse to the axis A1, i.e., not parallel to the axis A1. The second axis A2 may not be perpendicular to the axis A1. For example, the angle α defined by one of the axis A1 and the second axis A2 may be greater than 90 degrees, the angle being measured radially toward the roller 60 and axially toward the body 84.

[0021] refer to Figure 4 , the rollers 60 are radially spaced a common distance from the axis A1. For example, the radial distance from the axis A1 at the center of the head unit 58 to one of the rollers 60 is the same as the radial distance from the axis A1 at the center of the head unit 58 to another of the rollers 60. The common distance can be equal to the outer radius of the shell 40, for example, so that the rollers 60 can simultaneously abut the outer cylindrical body 46 of the shell 40. The rollers 60 are equidistant from each other around the axis A1. For example, the circumferential distance (e.g., angular distance) around the axis A1 between the first pair of rollers 60 can be equal to the circumferential distance around the axis between the second pair of rollers 60. The common distance from the axis A1 and the equal spacing around the axis A1 make it possible to balance the forces applied to the shell 40 from the press 56, for example, so that the rollers 60 apply forces along the axis A1 without applying unbalanced torque to the shell 40.

[0022] refer to Figures 5A to 6BEach roller 60 includes a pair of opposing end surfaces 64 and an outer circumferential surface 66. The end surfaces 64 of each roller 60 are spaced apart from the corresponding second axis A2. For example, the pin 62 supporting the roller 60 may extend from one of the end surfaces 64 through the roller 60 to the other of the end surfaces 64. The end surface 64, for example, extends radially outward from the pin 62 to the outer circumferential surface 66 of the corresponding roller 60. The outer circumferential surface 66 extends from one of the end surfaces 64 to the other of the end surfaces 64. The outer circumferential surface 66 surrounds the corresponding second axis A2.

[0023] refer to Figure 5B and Figure 6B The outer circumferential surface 66 includes an inlet portion 68, a top portion 70, and a middle portion 72 located therebetween. For example, the top portion 70 may be radially inward of the middle portion 72 relative to the second axis A2, and the inlet portion 68 may be radially outward of the middle portion 72. The outer circumferential surface 66 may include a bottom portion 74 radially outward of the inlet portion 68 relative to the second axis A2.

[0024] When the end portion 48 is bent from the initial position to the final position using the press 56 and the roller 60, the inlet portion 68 of the outer circumferential surface 66 of the roller 60 receives the end portion 48 of the shell 40. Figure 6A and Figure 6B As shown, the inlet portion 68 can contact the outer cylindrical body 46 of the housing 40. For example, when the roller 60 contacts the outer circumferential surface 66 of the housing 40, the inlet portion 68 extends parallel to the axis A1 of the press 56. A cross section is taken along a plane containing both the axis A1 of the press 56 and the second axis A2 of the roller 60. The inlet portion 68 can be linear in cross section, for example, extending between the middle portion 72 and the bottom portion 74. The roller 60 can include a curve, chamfer, and / or other inclined surface connecting the inlet portion 68 to the bottom portion 74.

[0025] A top portion 70 of the outer circumferential surface 66 of the roller 60 corresponds to the end 48 of the shell 40 in the final position. For example, the geometry of the top portion 70 can be very similar to the geometry of the end 48 of the shell 40. As another example, in cross section, the top portion 70 of the roller 60 can generally continuously abut the end 48 of the shell 40. The top portion 70 provides the final position of the end 48 of the shell 40. For example, after the end 48 is bent, the top portion 70 contacts the end 48 of the shell 40. For example, when the roller 60 contacts the end 48 of the shell 40 in the final position, the top portion 70 can extend perpendicular to the axis A1 of the press 56. The top portion 70 can be linear in cross section, for example, extending between the adjacent end surface 64 of the roller 60 and the middle portion 72 of the outer circumferential surface 66. The roller 60 can include a curve, chamfer, and / or other inclined surface connecting the end surface 64 to the bottom portion 70.

[0026] The middle position of the outer circumferential surface 66 of the roller 60 provides the shell middle portion 54. When the end 48 is in the end position, the middle portion 72 corresponds to the shell middle portion 54. For example, the geometry of the middle portion 72 can be very similar to the geometry of the shell middle portion 54. As another example, in cross section, the middle portion 72 of the roller 60 can generally continuously abut the shell middle portion 54 between the end 48 and the outer cylindrical body 46. In cross section, the middle portion 72 of the outer circumferential surface 66 extends linearly between the entrance portion 68 and the top portion 70. The middle portion 72 between the entrance portion 68 and the top portion 70 is at least as long as the wall thickness of the shell 40. In cross section, the middle portion 72 extends transverse to the axis A1. For example, the middle portion 72 and the axis A1 can define an angle between 25 degrees and 65 degrees (for example, as measured between the axis A1), and within this angular range, the roller 60 contacts the shell 40. The intermediate portion 72 extends circumferentially about the second axis A2 of the respective roller 60, for example, along the entire circumference of the outer circumferential surface 66. For example, the intermediate portion 72 may be frustoconical and centered about the respective second axis A2.

[0027] The outer circumferential surface 66 may include a first curve 76 between the middle portion 72 and the inlet portion 68, and / or a second curve 78 between the middle portion 72 and the top portion 70. The first curve 76 and the second curve 78 guide the housing 40 to bend from the inlet portion 68 to the middle portion 72, and from the middle portion 72 to the top portion 70. The radii of the first curve 76 and the second curve 78 may be predetermined, for example, based on the material of the housing 40, the wall thickness of the housing 40, etc.

[0028] The press 56 can include a central tube 80 extending downwardly from the head unit 58 along an axis A1. For example, the central tube 80 can press the body 42 downwardly, i.e., the roller 60 bends the end 48 of the housing 40. The central tube 80 can be spring-loaded and movable relative to the head unit 58 along the axis A1, e.g., with a spring urging the central tube 80 away from the body 84 of the press 56. The central tube 80 can include a central passage 82. A portion of the body 42 can be received in the central passage 82 of the central tube 80.

[0029] refer to Figure 7 , which shows a flow chart illustrating a process 700 for securing the housing 40 and the body 42 of the damper assembly 32. The housing 40 is secured to the body 42 without, i.e., the process 700 does not include, a welding operation.

[0030] The process 700 begins at block 710 where the component 44 is installed into the housing 40 before the end 48 of the housing 40 is bent inwardly, as shown. Figure 5A and Figure 5B 4. The components 44 can be installed manually, by machine or by other suitable methods.

[0031] Next, at block 720, the body 42 is installed into the blank space of the housing 40. The body 42 may be installed manually, by machine, or by other suitable methods.

[0032] Next, at block 730, the ends 48 of the housing 40 are pressed inwardly using the press 56 and roller 60. For example, the housing 40 can be positioned below the press 56 and aligned on the axis A1. The press 56 can then be actuated to an extended position while the roller 60 rotates about the axis A1. The middle portion 72 of the roller 60, starting from the housing middle portion 54, bends the ends 48 inwardly, thereby applying a preload force to the body 42 and component 44.

[0033] In the accompanying drawings, the same reference numerals indicate the same elements. In addition, some or all of these elements may be changed. With regard to the media, processes, systems, methods, etc. described herein, it should be understood that although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes may be put into practice in accordance with the steps performed in an order other than that described herein. It should be further understood that certain steps may be performed synchronously, other steps may be added, or certain steps described herein may be omitted. In other words, for the purpose of illustrating certain embodiments, a description of the processes herein is provided, and should in no way be interpreted as limiting the claimed invention.

[0034] The present disclosure has been described in an illustrative manner, and it should be understood that the terminology used is intended to be descriptive rather than limiting. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the present disclosure may be practiced in ways other than those specifically described.

Claims

1. An assembly for securing components of a damper assembly, comprising: a press movable along an axis from a retracted position to an extended position and configured to press downwardly on a component of the damper assembly; and a plurality of rollers rotatably supported at ends of the press; The roller has an outer circumferential surface including a middle portion that, in cross-section, is transverse to the axis and extends linearly between an inlet portion and a top portion of the outer circumferential surface, The plurality of rollers are configured to press the ends of the housing of the damper assembly inwardly under the driving of the press, so that the ends are bent inwardly.

2. The assembly of claim 1, wherein the inlet portion extends along the axis.

3. The assembly of claim 2, wherein the top portion extends perpendicular to the axis.

4. The assembly of claim 1, wherein the outer circumferential surface includes a curve between the intermediate portion and the inlet portion.

5. The assembly of claim 4, wherein the outer circumferential surface includes a second curve between the middle portion and the top portion.

6. The assembly of claim 1 wherein the press rotates about the axis and the rollers are spaced a common distance from the axis.

7. The assembly of claim 6, wherein the rollers are equally spaced from one another about the axis.

8. The assembly of claim 6, wherein the common distance is equal to the radius of the shell pressed by the roller.

9. The assembly of claim 1, wherein each of the rollers is rotatable about a respective one of a plurality of second axes.

10. The assembly of claim 9, wherein the second axis is transverse to the axis.

11. The assembly of claim 10, wherein the second axis is non-perpendicular to the axis.

12. The assembly of claim 9, wherein the intermediate portion extends circumferentially about the second axis.

13. The assembly of claim 1, wherein the intermediate portion and the axis define an angle between 25 degrees and 65 degrees.

14. The assembly of claim 1, wherein the intermediate portion between the inlet portion and the top portion is at least as long as the thickness of a wall of the housing pressed by the roller.

15. The assembly of claim 1, further comprising a valve assembly enclosed by a housing of the damper assembly.

16. The assembly of claim 15, wherein the valve assembly is secured to a stem of the damper assembly.

17. The assembly of claim 1, wherein the housing includes an outer cylindrical body, the end portion extending radially inwardly from the outer cylindrical body, the end portion corresponding to the top portion of the outer circumferential surface of the roller.

18. The assembly of claim 17, wherein the housing includes a housing mid-portion extending linearly between the end portions and the outer cylindrical body, the housing mid-portion corresponding to the mid-portion of the roller.

19. A method for fixing a housing of a damper assembly, comprising pressing a component of the damper assembly downward using a press, and pressing an end of the housing inward using a roller so that the end bends inward, the roller having an outer circumferential surface, the outer circumferential surface including a middle portion, and in cross section, the middle portion extending linearly between an entrance portion and a top portion of the outer circumferential surface.

20. The method of claim 19, wherein the housing is secured without a welding operation.

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