A method for manufacturing a light-weight liquid storage tank for a passenger vehicle and a liquid storage tank

Abstract

The application discloses a shock absorber part, and aims to provide a passenger car liquid storage cylinder lightweight manufacturing method and the liquid storage cylinder, which are convenient to process, reliable in structure, and low in overall quality. Technical scheme points are as follows: during processing of the liquid storage cylinder, a pressing roller die is used to tightly adhere to and fix the outside of the liquid storage cylinder, a spinning roller is arranged on the inside of the liquid storage cylinder, wall thickness of the liquid storage cylinder is changed by spinning the side wall of the liquid storage cylinder, so that the key position has a certain thickness to enhance the structural strength, the remaining part is lightened by using a relatively thin thickness, and the flatness and sealing performance of the inside of the liquid storage cylinder are detected after processing, so that consistency and reliability of the finished product structure are ensured, the problems of complex processing, low qualified rate and high quality in the production process of the traditional liquid storage cylinder are effectively solved, and the application is suitable for the technical field of automobile parts production.

Description

Technical Field

[0001] This invention relates to a shock absorber component, and more specifically, to a lightweight manufacturing method for a liquid reservoir in a passenger vehicle and the liquid reservoir itself. Background Technology

[0002] The reservoir is a core load-bearing and sealing component in a shock absorber, and is one of the important components for improving the handling and comfort of a vehicle. It is mainly used to store, separate, and filter system media. During installation and use, the sealing reliability and pressure-bearing performance of its structure are required to be high. Currently, reservoirs are usually manufactured by welding and stretching, but these processing methods are relatively complex. After processing, the inner wall of the reservoir will have many burrs. Welding will prolong the processing time, and the welding process is difficult to operate, which can easily lead to uneven welding and a low overall pass rate. Furthermore, due to the uncertainty of welding quality, the raw materials used for welding are usually thicker plates, which increases the overall cost and product weight, making it difficult to meet the requirements of lightweight equipment. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a lightweight manufacturing method and liquid storage tank for passenger vehicles that is easy to process, has a reliable structure, and has a low overall weight.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a lightweight manufacturing method for a passenger vehicle reservoir, comprising the following steps: S1, reservoir forming: based on the installation requirements of the shock absorber, reservoir parameters of corresponding dimensions are set, and the raw material is processed based on the set parameters to form a reservoir raw material with uniform wall thickness; S2, Wall thickness forming: The liquid storage cylinder raw material is installed in the pressure roller mold. The pressure roller mold is in close contact with the outer surface of the liquid storage cylinder raw material, and a spinning roller is provided on the inner side of the liquid storage cylinder for mutual squeezing with the side wall of the liquid storage cylinder. S3. Wall thickness parameter configuration: Based on the requirements of the vibration damper, the wall thickness of the liquid storage tank is configured; S4. Variable wall thickness forming: Based on the wall thickness parameters of the liquid storage cylinder, the spinning roller presses the side wall of the liquid storage cylinder while moving along the axial direction of the liquid storage cylinder. During the spinning process, the spinning roller detects the pre-input wall thickness parameters of the liquid storage cylinder. If the preset wall thickness parameters at the current position are low, the pressure applied by the spinning roller to the side wall of the liquid storage cylinder is increased; otherwise, the pressure applied by the spinning roller to the side wall of the liquid storage cylinder is decreased. S5. After spinning is completed, the inner wall of the liquid storage cylinder is inspected. If the inner wall of the liquid storage cylinder is flat, the current spinning of the liquid storage cylinder is deemed qualified; otherwise, the current spinning of the liquid storage cylinder is deemed unqualified. Based on the wall thickness parameters of the unqualified position, the corresponding pressure is used to press the side wall of the liquid storage cylinder.

[0005] The present invention is further configured such that the spinning method in step S4 includes the following steps: based on the pre-inputted wall thickness parameters and the material of the liquid storage cylinder, calculate the pressure required to spin the current liquid storage cylinder to the corresponding thickness, and perform spinning processing on the liquid storage cylinder based on the calculated pressure.

[0006] The present invention is further configured such that: in step S1, the processing of the raw material of the liquid storage cylinder is reserved for the increase in length after the variable wall thickness forming, so that the length of the liquid storage cylinder after the variable wall thickness forming is completed meets the design requirements.

[0007] The present invention is further configured such that step S5 also includes the installation of the liquid storage cylinder and the sealing test, including the following steps: S51, machining stop ends at both ends of the liquid storage cylinder, and sequentially installing a sealing structure and a fixing structure on the liquid storage cylinder; S52. After the liquid storage cylinder is processed, gas is introduced into the liquid storage cylinder, and the initial gas pressure P inside the liquid storage cylinder is detected at the same time. S53. Continuously introduce gas and check the internal pressure of the liquid storage tank again. If the pressure value increases, continue to introduce gas until the pressure value inside the liquid storage tank is 2P and then jump to S54 to continue the detection. Otherwise, if the pressure value remains unchanged, it is determined that the current liquid storage tank has poor sealing performance and needs to be reprocessed. S54. Stop the ventilation to maintain pressure in the liquid storage tank for a period of time H. S55. After time period H, check the pressure P1 inside the liquid storage tank. If P1 < 1.5P, it is determined that the liquid storage tank has poor sealing performance and the liquid storage tank needs to be reprocessed. Otherwise, the liquid storage tank has qualified sealing performance.

[0008] This application also discloses a liquid reservoir produced by a lightweight manufacturing method for a passenger vehicle liquid reservoir. The liquid reservoir includes a fixed structure and connecting structures disposed at both ends of the fixed structure. The ratio of the sidewall thickness of the connecting structure to the sidewall thickness of the fixed structure is 1:2.

[0009] Preferably, both ends of the liquid storage cylinder connection structure are provided with mounting stops, and the mounting stops include mounting slopes respectively provided on the inner / outer wall of the liquid storage cylinder.

[0010] Preferably, the outer wall of the liquid storage cylinder is provided with a sealing cap at one end where an installation slope is provided, the sealing cap is screwed and sealed with the liquid storage cylinder, and an installation bracket is welded to the other end of the liquid storage cylinder.

[0011] By adopting the above technical solution, the following beneficial effects are achieved: 1. In the processing of the liquid storage cylinder, this application uses a pressure roller mold to tightly fit and fix the outer side of the liquid storage cylinder, while a spinning roller is set on the inner side of the liquid storage cylinder. By spinning the side wall of the liquid storage cylinder, the variable wall thickness forming of the liquid storage cylinder is achieved. This allows key parts to have a certain thickness to enhance structural strength, while the remaining parts are made of thinner thickness to reduce weight. The liquid storage cylinder structure is integrally formed, eliminating the heat effect of the welded structure compared with the welded structure, avoiding product defects caused by process defects, and enabling single clamping during processing. The variable wall thickness forming process of the liquid storage cylinder simplifies the overall processing flow and shortens the processing time of a single product. The ratio of the thicker wall to the thinner wall of the liquid storage cylinder is 2:1, which ensures the overall strength of the fixed structure after installation while meeting the installation requirements of the connection structure. It meets the requirements of lightweight production while the overall structure has high strength. Furthermore, this application tests the flatness and sealing performance of the inside of the liquid storage cylinder after processing to ensure the consistency and reliability of the finished product structure. This effectively solves the problems of complex processing, low pass rate and high quality in the traditional liquid storage cylinder production process.

[0012] 2. Furthermore, this application, during the raw material production stage, reserves a margin for the increased length after variable wall thickness spinning based on the length of the finished liquid storage cylinder. This ensures that the final size accurately matches the installation requirements of the vibration damper, thereby reducing the subsequent cutting of the finished liquid storage cylinder, avoiding resource waste, and lowering production costs. During the variable wall thickness forming process, one side of the liquid storage cylinder is fixed to prevent movement during spinning. The pressure of the pressing roller on the inner side of the liquid storage cylinder is automatically adjusted based on a preset wall thickness parameter. Specifically, when the spinning roller moves to a position with a preset thicker wall thickness, the spinning roller squeezes the inner wall of the liquid storage cylinder with a smaller pressure. The continuous and smooth variable wall thickness distribution along the axial direction makes the connection points at both ends of the liquid storage cylinder relatively thin, achieving a lightweight design while flexibly cooperating with the sealing structure. The middle main body is relatively thick to withstand working pressure. Furthermore, the pressure control of the spinning roller is automatically set based on material parameters and wall thickness, resulting in a high degree of automation in the overall processing. It can be reused in the same processing flow, significantly reducing reliance on technical personnel. Finally, the entire liquid storage cylinder is inspected, and any unfinished, locally protruding areas are pressed again to improve the yield rate and ensure the dimensional accuracy and smoothness of the internal flow channels of the final product.

[0013] 3. Simultaneously, during the testing of the finished liquid storage tank, the tank is pressurized to twice its initial pressure to initially screen for tanks with more serious leaks. After pressurization, a pressure holding test is conducted within a specific time period, and a pressure holding value of not less than 1.5P is used as the qualified threshold. This effectively ensures the sealing performance of the liquid storage tank under the ultimate bearing pressure, guaranteeing the sealing effect of the finished product. In addition, stop ports are set on the inner / outer sides of both ends of the liquid storage tank, which are matched with the differentiated connection methods of spinning sealing and welding processes, taking into account both the overall sealing reliability and the ease of installation.

[0014] 4. Furthermore, during the configuration of the liquid storage cylinder structure, the ratio of the side wall thickness of the connecting structure to the side wall thickness of the fixed structure is 1:2. The fixed structure in the middle bears the main tensile, compressive, and bending loads, while the connecting structures at both ends are used for assembly and guidance. This ratio ensures that the liquid storage cylinder itself has strong resistance to deformation while reducing the overall weight. At the same time, the installation guides at both ends of the liquid storage cylinder can automatically center itself during assembly, reducing local stress concentration caused by installation eccentricity and enhancing the pressure resistance and service life of the liquid storage cylinder after installation. Attached Figure Description

[0015] Fig. 1 This is a flowchart illustrating a lightweight manufacturing method for a liquid reservoir in a passenger vehicle and an embodiment of the liquid reservoir, according to the present invention. Fig. 2 This is a flowchart illustrating a lightweight manufacturing method for a liquid reservoir in a passenger vehicle and a liquid reservoir installation and sealing test method according to an embodiment of the present invention. Fig. 3 This is a partial cross-sectional view of the liquid reservoir structure of a lightweight manufacturing method and embodiment of a liquid reservoir for passenger vehicles according to the present invention. Fig. 4 This is a schematic diagram of the liquid storage tank installation structure of a lightweight manufacturing method for a passenger vehicle liquid storage tank and an embodiment of the liquid storage tank according to the present invention; The attached diagram is labeled as follows: 1. Fixed structure; 2. Connecting structure; 3. Mounting stop; 4. Mounting ramp; 5. Sealing cover; 6. Mounting bracket. Detailed Implementation

[0016] Reference Figs. 1 to 4 The present invention provides a lightweight manufacturing method for a liquid reservoir in a passenger vehicle and an embodiment of the liquid reservoir.

[0017] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0018] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0019] A lightweight manufacturing method for a passenger vehicle reservoir includes the following steps: S1, reservoir forming: based on the installation requirements of the shock absorber, set reservoir parameters of corresponding size, and process the raw material based on the set parameters to form a reservoir raw material with uniform wall thickness; S2, Wall thickness forming: The liquid storage cylinder raw material is installed in the pressure roller mold. The pressure roller mold is in close contact with the outer surface of the liquid storage cylinder raw material, and a spinning roller is provided on the inner side of the liquid storage cylinder for mutual squeezing with the side wall of the liquid storage cylinder. S3. Wall thickness parameter configuration: Based on the requirements of the vibration damper, the wall thickness of the liquid storage tank is configured; S4. Variable wall thickness forming: Based on the wall thickness parameters of the liquid storage cylinder, the spinning roller presses the side wall of the liquid storage cylinder while moving along the axial direction of the liquid storage cylinder. During the spinning process, the spinning roller detects the pre-input wall thickness parameters of the liquid storage cylinder. If the preset wall thickness parameters at the current position are low, the pressure applied by the spinning roller to the side wall of the liquid storage cylinder is increased; otherwise, the pressure applied by the spinning roller to the side wall of the liquid storage cylinder is decreased. S5. After spinning is completed, the inner wall of the liquid storage cylinder is inspected. If the inner wall of the liquid storage cylinder is flat, the current spinning of the liquid storage cylinder is deemed qualified; otherwise, the current spinning of the liquid storage cylinder is deemed unqualified. Based on the wall thickness parameters of the unqualified position, the corresponding pressure is used to press the side wall of the liquid storage cylinder.

[0020] The spinning method in step S4 includes the following steps: based on the pre-inputted wall thickness parameters and the material of the liquid storage cylinder, calculate the pressure required to spin the current liquid storage cylinder to the corresponding thickness, and perform spinning processing on the liquid storage cylinder based on the calculated pressure.

[0021] In step S1, the processing of the raw material for the liquid storage cylinder is designed to allow for an increase in length after the variable wall thickness molding, so that the length of the liquid storage cylinder after the variable wall thickness molding is completed meets the design requirements.

[0022] Step S5 also includes the installation of the liquid storage cylinder and the sealing test, including the following steps: S51, machining stop ends at both ends of the liquid storage cylinder, and installing the sealing structure and the fixing structure on the liquid storage cylinder in sequence; S52. After the liquid storage cylinder is processed, gas is introduced into the liquid storage cylinder, and the initial gas pressure P inside the liquid storage cylinder is detected at the same time. S53. Continuously introduce gas and check the internal pressure of the liquid storage tank again. If the pressure value increases, continue to introduce gas until the pressure value inside the liquid storage tank is 2P and then jump to S54 to continue the detection. Otherwise, if the pressure value remains unchanged, it is determined that the current liquid storage tank has poor sealing performance and needs to be reprocessed. S54. Stop the ventilation to maintain pressure in the liquid storage tank for a period of time H. S55. After time period H, check the pressure P1 inside the liquid storage tank. If P1 < 1.5P, it is determined that the liquid storage tank has poor sealing performance and the liquid storage tank needs to be reprocessed. Otherwise, the liquid storage tank has qualified sealing performance.

[0023] This application also discloses a liquid reservoir produced by a lightweight manufacturing method for a passenger vehicle liquid reservoir. The liquid reservoir includes a fixed structure 1 and a connecting structure 2 disposed at both ends of the fixed structure 1. The ratio of the side wall thickness of the connecting structure 2 to the side wall thickness of the fixed structure 1 is 1:2.

[0024] Preferably, both ends of the liquid storage cylinder connecting structure 2 are provided with mounting stops 3, and the mounting stops 3 include mounting inclined surfaces 4 respectively provided on the inner / outer wall of the liquid storage cylinder.

[0025] Preferably, the outer wall of the liquid storage cylinder is provided with a sealing cap 5 at one end where the mounting inclined surface 4 is provided. The sealing cap 5 is screwed and sealed with the liquid storage cylinder, and the other end of the liquid storage cylinder is welded with a mounting bracket 6.

[0026] In the processing of the liquid storage cylinder, this application uses a pressure roller mold to tightly fix the outer side of the liquid storage cylinder, while a spinning roller is set on the inner side of the liquid storage cylinder. By spinning the side wall of the liquid storage cylinder, the variable wall thickness of the liquid storage cylinder is formed. This allows key parts to have a certain thickness to enhance structural strength, while the remaining parts are thinner to reduce weight. The liquid storage cylinder structure is integrally formed, eliminating the heat effect of the welded structure compared with the welded structure, avoiding product defects caused by process defects. The variable wall thickness forming of the liquid storage cylinder can be achieved in a single clamping process, simplifying the overall processing flow and shortening the processing time of a single product. Moreover, the ratio of the thicker wall to the thinner wall of the liquid storage cylinder is 2:1, which ensures the overall strength of the fixing structure 1 after installation while meeting the installation requirements of the connecting structure 2. This meets the requirements of lightweight production, while the overall structure has high strength. Furthermore, after processing, this application tests the flatness and sealing performance of the inside of the liquid storage cylinder to ensure the consistency and reliability of the finished product structure. This effectively solves the problems of complex processing, low pass rate and high quality in the traditional liquid storage cylinder production process.

[0027] Furthermore, this application, during the raw material production stage, reserves a margin for the increased length after variable wall thickness spinning based on the length of the finished liquid storage cylinder. This ensures that the final dimensions accurately match the vibration damper installation requirements, thereby reducing the subsequent cutting of the finished liquid storage cylinder, avoiding resource waste, and lowering production costs. During the variable wall thickness forming process, one side of the liquid storage cylinder is fixed to prevent movement during spinning. The pressure of the pressing roller on the inner side of the liquid storage cylinder is automatically adjusted based on a preset wall thickness parameter. Specifically, when the spinning roller moves to a position with a preset thicker wall thickness, the spinning roller squeezes the inner wall of the liquid storage cylinder with a smaller pressure, thereby... A continuous and smooth variable wall thickness distribution is formed along the axial direction, making the connection points at both ends of the liquid storage cylinder relatively thin. This achieves a lightweight design while allowing for flexible cooperation with the sealing structure. The main body in the middle is relatively thick to withstand working pressure. Furthermore, the pressure control of the spinning roller is automatically set based on material parameters and wall thickness, resulting in a high degree of automation in the overall processing. It can be reused in the same processing flow, significantly reducing reliance on technical personnel. Finally, the entire liquid storage cylinder is inspected, and any unfinished, locally protruding areas are pressed again to improve the yield rate and ensure the dimensional accuracy and smoothness of the internal flow channels of the final product.

[0028] Meanwhile, during the testing of the finished liquid storage tank, the tank is pressurized to twice its initial pressure to initially screen for tanks with more serious leaks. After pressurization, a pressure holding test is conducted within a specific time period, and a pressure holding value of not less than 1.5P is used as the qualified threshold. This effectively ensures the sealing performance of the liquid storage tank under the ultimate bearing pressure, guaranteeing the sealing effect of the finished product. In addition, the inner / outer sides of both ends of the liquid storage tank are equipped with stop ports, which are matched with the spin sealing and welding process to achieve differentiated connection methods, taking into account both the reliability of the overall seal and the convenience of installation.

[0029] Furthermore, during the configuration of the liquid storage cylinder structure, the ratio of the sidewall thickness of the connecting structure 2 to the sidewall thickness of the fixing structure 1 is 1:2. The middle fixing structure 1 bears the main tensile, compressive, and bending loads, while the connecting structures 2 at both ends are used for assembly and guidance. This ratio ensures that the liquid storage cylinder itself has strong resistance to deformation while reducing the overall weight. Simultaneously, the installation guides at both ends of the liquid storage cylinder can automatically center itself during assembly, reducing local stress concentration caused by installation eccentricity and enhancing the pressure resistance and service life of the liquid storage cylinder after installation. The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Ordinary variations and substitutions made by those skilled in the art within the scope of the present invention should be included within the protection scope of the present invention.

Claims

1. A lightweight manufacturing method for a liquid reservoir in a passenger vehicle, characterized in that, The process includes the following steps: S1, Liquid storage cylinder forming: Based on the installation requirements of the vibration damper, set the parameters of the liquid storage cylinder of the corresponding size, and process the raw material based on the set parameters to form a liquid storage cylinder raw material with uniform wall thickness; S2, Wall thickness forming: The liquid storage cylinder raw material is installed in the pressure roller mold. The pressure roller mold is in close contact with the outer surface of the liquid storage cylinder raw material, and a spinning roller is provided on the inner side of the liquid storage cylinder for mutual squeezing with the side wall of the liquid storage cylinder. S3. Wall thickness parameter configuration: Based on the requirements of the vibration damper, the wall thickness of the liquid storage tank is configured; S4. Variable wall thickness forming: Based on the wall thickness parameters of the liquid storage cylinder, the spinning roller presses the side wall of the liquid storage cylinder while moving along the axial direction of the liquid storage cylinder. During the spinning process, the spinning roller detects the pre-input wall thickness parameters of the liquid storage cylinder. If the preset wall thickness parameters at the current position are low, the pressure applied by the spinning roller to the side wall of the liquid storage cylinder is increased; otherwise, the pressure applied by the spinning roller to the side wall of the liquid storage cylinder is decreased. S5. After spinning is completed, the inner wall of the liquid storage cylinder is inspected. If the inner wall of the liquid storage cylinder is flat, the current spinning of the liquid storage cylinder is deemed qualified; otherwise, the current spinning of the liquid storage cylinder is deemed unqualified. Based on the wall thickness parameters of the unqualified position, the corresponding pressure is used to press the side wall of the liquid storage cylinder.

2. The lightweight manufacturing method for a passenger vehicle liquid reservoir according to claim 1, characterized in that, The spinning method in step S4 includes the following steps: based on the pre-inputted wall thickness parameters and the material of the liquid storage cylinder, calculate the pressure required to spin the current liquid storage cylinder to the corresponding thickness, and perform spinning processing on the liquid storage cylinder based on the calculated pressure.

3. The lightweight manufacturing method for a passenger vehicle liquid reservoir according to claim 1, characterized in that, In step S1, the processing of the raw material for the liquid storage cylinder is designed to allow for an increase in length after the variable wall thickness molding, so that the length of the liquid storage cylinder after the variable wall thickness molding is completed meets the design requirements.

4. The lightweight manufacturing method for a passenger vehicle liquid reservoir according to claim 1, characterized in that, Step S5 also includes the installation of the liquid storage cylinder and the sealing test, including the following steps: S51, machining stop ends at both ends of the liquid storage cylinder, and installing the sealing structure and the fixing structure on the liquid storage cylinder in sequence; S52. After the liquid storage cylinder is processed, gas is introduced into the liquid storage cylinder, and the initial gas pressure P inside the liquid storage cylinder is detected at the same time. S53. Continuously introduce gas and check the internal pressure of the liquid storage tank again. If the pressure value increases, continue to introduce gas until the pressure value inside the liquid storage tank is 2P and then jump to S54 to continue the detection. Otherwise, if the pressure value remains unchanged, it is determined that the current liquid storage tank has poor sealing performance and needs to be reprocessed. S54. Stop the ventilation to maintain pressure in the liquid storage tank for a period of time H. S55. After time period H, check the pressure P1 inside the liquid storage tank. If P1 < 1.5P, it is determined that the liquid storage tank has poor sealing performance and the liquid storage tank needs to be reprocessed. Otherwise, the liquid storage tank has qualified sealing performance.

5. A liquid reservoir manufactured using a lightweight manufacturing method for a passenger vehicle liquid reservoir according to any one of claims 1-4, characterized in that, The liquid storage cylinder includes a fixed structure (1) and a connecting structure (2) disposed at both ends of the fixed structure (1). The ratio of the side wall thickness of the connecting structure (2) to the side wall thickness of the fixed structure (1) is 1:

2.

6. The liquid reservoir produced by the lightweight manufacturing method for a passenger vehicle liquid reservoir according to claim 5, characterized in that, The liquid storage cylinder connecting structure (2) is provided with mounting stops (3) at both ends. The mounting stops (3) include mounting inclined surfaces (4) respectively provided on the inner / outer wall of the liquid storage cylinder.

7. The liquid reservoir produced by the lightweight manufacturing method for a passenger vehicle liquid reservoir according to claim 6, characterized in that, The outer wall of the liquid storage cylinder is provided with a mounting inclined surface (4) and a sealing cap (5) is provided at one end. The sealing cap (5) is screwed and sealed with the liquid storage cylinder. The other end of the liquid storage cylinder is welded with a mounting bracket (6).

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