A coupling damper for a pro-active stabilizer and a manufacturing method thereof

Abstract

The application discloses a shaft coupling shock absorber for an active stabilizer bar and a manufacturing method thereof, and belongs to the technical field of automobile chassis suspensions. The shaft coupling shock absorber comprises an inner framework having a connecting portion extending in an axial direction, a rubber body made of hydrogenated nitrile rubber (HNBR), the rubber body being vulcanized and bonded to the outer periphery of the inner framework, and a flange being sleeved and fixed to the connecting portion of the inner framework and being pressed against the end face of the rubber body. The manufacturing method comprises the following steps: annealing, machining and quenching and tempering of the inner framework preform; degreasing, shot blasting and adhesive coating treatment of the quenched and tempered inner framework; injection molding of the HNBR rubber by means of an injection vulcanizing machine, so that the rubber body is vulcanized and bonded to the outer periphery of the inner framework; and interference press fitting of the flange to the connecting portion of the inner framework. The application has the advantages of wide-temperature-range adaptability, high fatigue life and low cost through the comprehensive innovation of materials, structures and processes, and is suitable for an active stabilizer bar system of a new energy automobile.

Description

Technical Field

[0001] This invention relates to the field of automotive chassis suspension system technology, and in particular to a coupling damper for an active stabilizer bar and its manufacturing method, belonging to the technical field of key components for intelligent chassis of new energy vehicles. Background Technology

[0002] With the rapid development of new energy vehicles, users are increasingly demanding higher levels of chassis handling and comfort. Active Anti-roll Bars (AARBs), as core components of intelligent chassis systems, can adjust their stiffness in real time according to the vehicle's driving conditions, suppressing body roll while maintaining straight-line driving comfort. They have become an important feature in mid-to-high-end new energy vehicles.

[0003] The active stabilizer bar coupling damper is a key component connecting the stabilizer bar body and the motor actuator. Its main functions include: transmitting the dynamic torque output by the motor, buffering high-frequency vibrations during driving, and adapting to the nonlinear mechanical characteristics required for dynamic stiffness adjustment. Because the operating conditions of active stabilizers are more demanding than those of traditional passive stabilizers—dynamic stress is approximately 15% higher, the operating temperature range is wider (-40℃-120℃), and it withstands high-frequency alternating loads—extremely high requirements are placed on the mechanical properties, durability, and NVH performance of the damper's rubber components.

[0004] Currently, existing stabilizer bar bushings (such as CN207088899U) are mainly designed for passive stabilizer bars. Their rubber materials are generally ordinary natural rubber or general-purpose synthetic rubber, which cannot meet the stringent operating requirements of active stabilizer bars in terms of high temperature resistance, fatigue resistance, and electrolytic corrosion resistance. In addition, traditional mating bushings have complex structures and high costs, which is not conducive to the popularization of active stabilizer bar technology in mid-to-low-end vehicles.

[0005] Therefore, there is an urgent need to develop a coupling damper specifically for active stabilizer bars, which can meet the comprehensive performance requirements of adjustable dynamic stiffness, resistance to alternating torque, and stability over a wide temperature range in terms of material formulation, structural design, and manufacturing process. Summary of the Invention

[0006] This invention addresses the shortcomings of existing technologies by providing a coupling damper for active stabilizer bars and its manufacturing method. The aim is to achieve high durability, wide temperature range adaptability, and low-cost manufacturing of the damper through material innovation, structural optimization, and process improvement.

[0007] To achieve the above-mentioned objectives, the present invention provides the following technical solution:

[0008] This invention provides a coupling damper for an active stabilizer bar, comprising:

[0009] The inner frame has connecting parts that extend along the axial direction;

[0010] The rubber body is made of hydrogenated nitrile butadiene rubber (HNBR), and the rubber body is vulcanized and bonded to the outer periphery of the inner skeleton;

[0011] The flange is fitted and fixed to the connecting part of the inner skeleton and presses against the end face of the rubber body.

[0012] Preferably, the inner frame includes a base and a frame integrally connected to the base.

[0013] Preferably, the base is a hollow columnar structure, which includes a base plate, a chassis, and a frame connecting the two.

[0014] Preferably, the frames are spaced apart circumferentially to form perforations between adjacent frames.

[0015] Preferably, the skeleton includes a connecting column and a plurality of columns, the plurality of columns being distributed at intervals around the outer periphery of the connecting column.

[0016] Preferably, the columns are evenly distributed around the circumference of the connecting column, and the plurality of columns are arranged in a cross shape in the axial direction.

[0017] Preferably, the cross-section of the column is a trapezoidal shape with rounded corners and a smaller inner end and a larger outer end.

[0018] Preferably, the dynamic stiffness adjustment range of the rubber body is ≥200%, the fatigue life is ≥1 million cycles, and the applicable temperature range is -40℃ to 120℃.

[0019] The present invention also provides a method for manufacturing the above-mentioned coupling damper for an active stabilizer bar, comprising the following steps:

[0020] The prefabricated internal skeleton is subjected to annealing, machining, and quenching and tempering in sequence.

[0021] The steps include degreasing and shot blasting the heat-treated inner skeleton in sequence, and applying an adhesive to the predetermined bonding surface of the inner skeleton.

[0022] The process involves placing the inner skeleton coated with adhesive into a mold, and then injecting HNBR rubber into the inner skeleton using an injection vulcanizing machine, thereby vulcanizing and bonding the rubber body to the outer periphery of the inner skeleton.

[0023] The step of pressing the flange into the connection part of the inner skeleton so that the flange abuts against the end face of the rubber body.

[0024] Preferably, the prefabricated inner skeleton is made of 20MnCr5 bar stock.

[0025] Compared with the prior art, the advantages and beneficial effects of the present invention are as follows:

[0026] 1. Breakthrough in material performance: HNBR rubber is selected as the rubber body material, combined with 20MnCr5 alloy steel inner skeleton, which enables the shock absorber to have excellent high and low temperature resistance (-40℃~120℃), fatigue resistance (≥1 million cycles) and oil and aging resistance, which can meet the harsh working conditions of active stabilizer bars.

[0027] 2. Structural innovation: By setting a flange to fit into the inner skeleton connection part and press against the end face of the rubber body, the axial limit and pre-compression of the rubber body are realized, which improves the ability to withstand dynamic alternating loads; the base adopts a hollow structure, which achieves lightweight while ensuring strength.

[0028] 3. Process optimization: The heat treatment process of "annealing → machining → tempering" is adopted to improve the machinability and final mechanical properties of the material; shot blasting is used to increase the bonding surface area and roughness, and injection vulcanization process is used to ensure the bonding strength between the rubber body and the inner skeleton.

[0029] 4. Cost advantage: The use of a single bushing structure instead of the traditional mating bushing simplifies the assembly process, reduces material and manufacturing costs, and helps to promote active stabilizer bar technology to mid-to-low-end models.

[0030] 5. Filling a domestic gap: It broke the dependence on imports, realized the localization of core materials for active stabilizer bar coupling dampers, and improved the self-controllability of the supply chain. Attached Figure Description

[0031] Figure 1 This is a front view schematic diagram of the internal skeleton structure of the present invention;

[0032] Figure 2 for Figure 1 A schematic diagram of the AA cross-sectional structure;

[0033] Figure 3 for Figure 2 Schematic diagram of the BB cross-sectional structure;

[0034] Figure 4 This is a rear view schematic diagram of the internal skeleton structure of the present invention;

[0035] Figure 5 This is a side view of the base structure of the inner frame of the present invention;

[0036] Figure 6 This is a schematic cross-sectional view of the inner skeleton and rubber body after vulcanization.

[0037] Figure 7 for Figure 6A schematic diagram of the right-side view structure;

[0038] Figure 8 for Figure 6 A schematic diagram of the left-side view structure;

[0039] Figure 9 This is a schematic perspective view of the overall structure of the coupling damper for active stabilizer bars according to the present invention.

[0040] Figure 10 This is a schematic diagram of the overall discrete structure of the coupling damper for active stabilizer bar according to the present invention;

[0041] Figure 11 This is a three-dimensional structural diagram of the flange of the present invention;

[0042] Figure 12 This is a first side view of the flange structure of the present invention;

[0043] Figure 13 This is a schematic diagram of the second side view of the flange of the present invention;

[0044] Figure 14 for Figure 13 CC cross-sectional view of the structure;

[0045] The component numbers and their corresponding names in the diagram are as follows:

[0046] 1. Inner frame; 2. Rubber body; 3. Flange; 11. Base; 12. Frame; 111. Seat plate; 112. Chassis; 113. Frame body; 121. Connecting column; 122. Column. Detailed Implementation

[0047] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and embodiments. The following embodiments are for illustrative purposes only and should not be considered as limiting the scope of the present invention.

[0048] Example

[0049] like Figure 9 and Figure 10 As shown, this embodiment provides a coupling damper for an active stabilizer bar, which mainly includes three parts: an inner frame 1, a rubber body 2, and a flange 3.

[0050] Internal skeleton structure:

[0051] Combination Figures 1-5 The inner frame 1 is made of 20MnCr5 alloy steel bar and is in the shape of a rotating body with connecting parts extending along the axial direction. Specifically, the inner frame 1 includes a base 11 and a frame 12 integrally connected to the base 11.

[0052] The base 11 has a hollow columnar structure, which includes a base plate 111, a chassis 112, and a frame 113 connecting the base plate 111 and the chassis 112. The frame 113 is distributed circumferentially, and multiple frame 113 form hollow holes. This structure ensures that the base 11 has sufficient structural strength while achieving lightweight, which helps to reduce the unsprung mass of the whole vehicle.

[0053] The frame 12 includes a connecting column 121 and multiple columns 122. One end of the connecting column 121 is integrally connected to the base plate 111 of the base 11, and the other end extends axially to form a connecting portion for connecting the flange 3. Multiple columns 122 are evenly distributed around the outer periphery of the connecting column 121, and each column 122 extends axially. In this embodiment, there are four columns 122, evenly distributed circumferentially along the connecting column 121, forming a cross-shaped distribution axially. The cross-section of each column 122 is a trapezoidal shape with rounded corners, smaller at the inner end and larger at the outer end; that is, the width of the column 122 gradually increases from the root to the end, and the corners are rounded. This shape, while ensuring structural strength, helps reduce stress concentration and improve fatigue resistance.

[0054] Rubber body:

[0055] Combination Figures 6-8 The rubber body 2 is made of hydrogenated nitrile butadiene rubber (HNBR) and covers the outer periphery of the skeleton 12 of the inner skeleton 1. The rubber body 2 is tightly bonded to the inner skeleton 1 to form an integral structure through a vulcanization process. HNBR rubber has excellent oil resistance, high temperature resistance (can work for a long time in the range of -40℃ to 120℃), fatigue resistance and aging resistance. Its dynamic stiffness adjustment range can reach more than 200%, and its fatigue life is not less than 1 million cycles.

[0056] Flange:

[0057] Combination Figures 11-14 Flange 3 is machined from ordinary carbon steel, and its center has a mounting hole that matches the connecting post 121 of the inner frame 1. Flange 3 is fitted onto the connecting post 121 of the inner frame 1 and fixed by interference fit (press fit), and the end face of flange 3 presses against the end face of rubber body 2, which plays a role in axial limiting and pre-compression of rubber body 2.

[0058] The manufacturing method of the above-mentioned coupling damper specifically includes the following steps:

[0059] Step S1: Annealing treatment. The 20MnCr5 bar stock used for machining the inner skeleton 1 is annealed to reduce the material hardness and improve ductility, making it easier for subsequent machining and forming.

[0060] Step S2: Machining. The annealed bar stock is machined to the predetermined dimensions to form the prefabricated inner skeleton 1 with the above structure; at the same time, the steel bar stock of the flange 3 is machined. In this step, the connecting column 121 of the inner skeleton 1 is provided with machining allowance.

[0061] Step S3: Quenching and tempering. The machined inner frame 1 and flange 3 are quenched and tempered (quenching + high-temperature tempering) to improve their overall mechanical properties, giving them strong resistance to deformation and meeting the dimensional stability requirements under heavy load conditions.

[0062] Step S4: Degreasing treatment. The inner skeleton 1 and flange 3 after heat treatment are degreased to remove oil, cutting fluid and other contaminants adhering to the surface, ensuring the quality of subsequent surface treatment.

[0063] Step S5: Shot blasting. Only the inner skeleton 1 (excluding flange 3) is shot blasted to remove the oxide scale on its surface and increase the surface roughness. After shot blasting, the specific surface area of ​​the predetermined bonding surface of the inner skeleton 1 (i.e., the outer peripheral surface of skeleton 12) increases, which is beneficial for forming a stronger mechanical interlocking force and bonding strength with the rubber body 2.

[0064] Step S6: Apply adhesive. Apply a layer of hot vulcanizing adhesive to the outer peripheral surface of the inner skeleton 12 (i.e., the surface in contact with the rubber body 2) after shot blasting to prepare for subsequent rubber vulcanization and bonding.

[0065] Step S7: Injection Curing. The inner skeleton 1 coated with adhesive is placed into the mold cavity of the injection curing machine. After mold closing, HNBR rubber compound is injected into the mold cavity under high pressure while heated and molten, filling the gap between the outer periphery of the inner skeleton 12 and the mold. Under high temperature (typically 160℃~200℃) and high pressure conditions, the HNBR rubber undergoes a cross-linking curing reaction, and the adhesive is activated, causing the rubber body 2 and the inner skeleton 1 to be firmly bonded together through chemical bonds. After curing, the mold is opened and the inner skeleton 1 assembly with the rubber body 2 is removed.

[0066] Step S8: Assembly. Place the vulcanized inner skeleton 1 and rubber body 2 assembly on the press fitting fixture, and press the flange 3 onto the connecting column 121 of the inner skeleton 1 by interference fit, so that the end face of the flange 3 is tightly pressed against the end face of the rubber body 2, thus completing the assembly of the entire coupling damper.

[0067] The active stabilizer bar coupling damper prepared by the above steps showed excellent performance in the installation test: the dynamic stiffness adjustment met the design requirements in a wide temperature range of -40℃ to 120℃; after 1 million fatigue tests, the rubber body showed no cracks or debonding, and the connection between the flange and the inner skeleton was reliable, fully meeting the requirements of vehicle assembly and use of the active stabilizer bar.

[0068] Comparative example:

[0069] Commercially available ordinary nitrile butadiene rubber (NBR) was used instead of HNBR as the rubber body material, with the remaining structure remaining the same as in this embodiment. In high-temperature fatigue tests above 80°C, the NBR rubber body exhibited surface cracking and stiffness reduction after approximately 300,000 cycles, failing to meet the design requirement of 1 million fatigue cycles. This demonstrates that the use of HNBR rubber combined with a specific structural design and manufacturing process in this invention resulted in a significant performance improvement.

[0070] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A coupling damper for an active stabilizer bar, characterized in that, include: The inner frame (1) has a connecting part that extends along the axial direction; The rubber body (2) is made of hydrogenated nitrile rubber and is vulcanized and bonded to the outer periphery of the inner skeleton (1); The flange (3) is fitted and fixed to the connecting part of the inner skeleton (1) and presses against the end face of the rubber body (2).

2. The coupling damper for an active stabilizer bar according to claim 1, characterized in that, The inner frame (1) includes a base (11) and a frame (12) integrally connected to the base (11).

3. The coupling damper for an active stabilizer bar according to claim 2, characterized in that, The base (11) is a hollow columnar structure, which includes a seat plate (111), a base plate (112), and a frame (113) connecting the two.

4. The coupling damper for an active stabilizer bar according to claim 3, characterized in that, The frames (113) are distributed circumferentially to form perforations between adjacent frames (113).

5. The coupling damper for an active stabilizer bar according to claim 2, characterized in that, The skeleton (12) includes a connecting column (121) and a plurality of columns (122), the plurality of columns (122) being distributed at intervals around the outer periphery of the connecting column (121).

6. The coupling damper for an active stabilizer bar according to claim 5, characterized in that, The columns (122) are evenly distributed around the circumference of the connecting column (121), and the plurality of columns (122) are arranged in a cross shape in the axial direction.

7. The coupling damper for an active stabilizer bar according to claim 5, characterized in that, The cross-section of the column (122) is a trapezoid with rounded corners, smaller at the inner end and larger at the outer end.

8. The coupling damper for an active stabilizer bar according to any one of claims 1 to 7, characterized in that, The dynamic stiffness adjustment range of the rubber body (2) is ≥200%, the fatigue life is ≥1 million cycles, and the applicable temperature range is -40℃ to 120℃.

9. A method for manufacturing a coupling damper for an active stabilizer bar as described in any one of claims 1 to 8, characterized in that, include: The prefabricated inner skeleton (1) is subjected to annealing, machining and heat treatment in sequence; The steps of degreasing and shot blasting the heat-treated inner skeleton (1) in sequence, and applying adhesive to the predetermined bonding surface of the inner skeleton (1); The inner skeleton (1) coated with adhesive is placed in a mold, and HNBR rubber is injected into it using an injection vulcanizing machine, so that the rubber body (2) is vulcanized and bonded to the outer periphery of the inner skeleton (1). The step of press-fitting the flange (3) into the connection part of the inner skeleton (1) so that the flange (3) abuts against the end face of the rubber body (2).

10. The manufacturing method according to claim 9, characterized in that, The prefabricated inner skeleton (1) is made of 20MnCr5 bar stock.

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