Method and arrangement for manufacturing a stabilizer with an integrated stabilizer bearing

Abstract

Method for manufacturing a stabilizer with at least one integrated stabilizer bearing, in particular two integrated stabilizer bearings, comprising the steps: (a) Providing a stabilizer bar with a suitable shape and structure, (b) Providing two elastomeric partial shells per stabilizer bearing, the inner contour of which is adapted to the cross-section of the stabilizer bar in the intended mounting area, (c) Providing at least one clamp element adapted to the outer contour of the elastomer sub-shells of the corresponding stabilizer bearing for enclosing at least the majority of the circumference of the elastomer sub-shells, (d) Local heating of the stabilizer bar in the area of ​​the mounting of the stabilizer bearing(s) to a predetermined final temperature, (e) Inserting the clamp element and a first elastomer partial shell into an upper or lower tool and at least the second elastomer partial shell into a lower or upper tool opposite the upper or lower tool of a joining press, (f) Closing the upper and lower tools and pressing the clamp element or elements and the elastomer partial shells with the stabilizer bar between the upper and lower tools for a predetermined time and with a predetermined pressure to form a positive connection at least between the stabilizer bar and the elastomer partial shells and (g) Opening the upper and lower tool and removing and cooling the stabilizer bar with the at least one integrated stabilizer bearing, characterized in that after step (f) or step (g) a step (g1) of reheating the stabilizer bar is carried out on both sides of the stabilizer bearing or each attached stabilizer bearing.

Description

[0001] The invention relates to a method and an arrangement for manufacturing a stabilizer with an integrated stabilizer bearing.

[0002] Stabilizer bars in the chassis of road vehicles serve to improve handling and driving safety and have been known in various designs and mounting configurations for decades. They are held in stabilizer bearings, which are attached to the vehicle body. Such stabilizer bearings typically comprise elastomer elements, especially made of rubber compounds, which essentially completely surround the stabilizer bar at the mounting point and serve to dampen vibrations and noise, as well as to increase the service life of the stabilizer assembly.

[0003] Stabilizers with integrated stabilizer bearings have become established in practice for some time now. Several well-known methods exist for their manufacture.

[0004] From DE 10 2009 011 818 A1 and US 2016 / 0257178 A1, corresponding methods comprising the features of the preamble of claim 1, as well as arrangements for carrying out these methods, are known. DE 10 2014 108 868 A1 and JP 2006-290313 A are further cited as relevant prior art.

[0005] The object of the invention is to provide an improved method and a correspondingly improved arrangement for the manufacture of such stabilizers with integrated stabilizer bearings, with which, compared to known systems, in particular energy savings and / or a reduction in tooling costs can be achieved.

[0006] This problem is solved in its method aspect by a method with the features of claim 1 and in its apparatus aspect by an arrangement with the features of claim 12. Advantageous further developments of the inventive concept are the subject of the respective dependent claims.

[0007] The invention includes the concept of selectively heating a ready-to-use stabilizer bar with a shape and microstructure adapted to the intended application in those areas where one or more stabilizer bearings are to be installed, and then joining it to the stabilizer bearing components in the locally heated state. It further includes the concept of inserting both the elastomeric shells of the stabilizer bearing and at least one clamp element belonging to the stabilizer bearing into the tooling of an assembly press, subsequently inserting the stabilizer bar, and then closing the tool and applying a suitable pressing force to the inserted components for a suitable duration.

[0008] A desired material-bonded connection between the stabilizer rod and the elastomer partial shells (usually half-shells) at the mounting location of the stabilizer bearing(s) is largely formed already in the joining press, but the process continues even after the complete stabilizer rod (with integrated bearing(s)) is removed under the influence of the clamp elements (or a single clamp element and an additional fixing agent) while the stabilizer rod cools down.

[0009] According to the invention, after step (f) or step (g) according to claim 1, a step (g1) of reheating the stabilizer rod is carried out on both sides of the stabilizer bearing or bearings attached. This step (g1) is expediently carried out by means of inductive heating or radiant heating, in particular by means of near-infrared radiation.

[0010] Typically, in the method according to the invention, a powder-coated stabilizer bar and rubber half-shells are used as components of the stabilizer bearing. However, in principle, uncoated stabilizer bars or those surface-treated in ways other than powder coating can also be treated according to the invention, and elastomer bearing components that do not have a half-shell shape and are not made of rubber can also be used.

[0011] In a design adapted to conventional forms of stabilizer bearings, step (c) comprises providing two clamp elements per stabilizer bearing, each shaped such that the two clamp elements together substantially completely enclose the elastomer partial shells.

[0012] The method can also be carried out with stabilizer bearings comprising a single clamp element, and in this case, after step (f), a step (fl) of temporarily fixing the single clamp element externally to the circumference of the elastomer partial shells is performed. For this fixing, for example, clamps or elastic bands known per se can be used, and the fixing is preferably released after the complete stabilizer has cooled.

[0013] In a preferred method, in step (d) inductive local heating is carried out using induction coils brought to the surface of the stabilizer rod. Inductive heating is a particularly selective and efficient method for stabilizer rods, which are typically made of steel. However, the required local heating can also be achieved by radiation or contact heating, or similar methods.

[0014] In one embodiment of the invention, the outer surface of the stabilizer bar, at least in the area of ​​the attachment of the stabilizer bearing(s), or the inner surfaces of the elastomer partial shells that contact the stabilizer bar in the assembled state, are coated with an adhesion promoter and / or polymerization agent. Depending on the material and any surface coating of the stabilizer bar and the elastomer partial shells, this embodiment can provide a further improvement in quality and / or enable a reduction in cycle time and thus an increase in the productivity of the process.

[0015] Comparable effects can be achieved in a further embodiment in which, after step (d), a step (d1) of heating at least the inner surfaces of the elastomer partial shells that contact the stabilizer rod in the joined state is carried out to a predetermined temperature. This step is carried out in particular as radiative heating, especially by means of near-infrared radiation.

[0016] Overall, in the proposed methods, the predetermined final temperature in step (d), the predetermined pressing time and pressing pressure in step (f), and optionally the heating temperature of the elastomer partial shells in the optional step (d1) are predetermined in such a way that a materially bonded connection is created between the stabilizer rod and the elastomer partial shells without any change to the microstructure of the stabilizer rod or damage to an optional powder coating.

[0017] It should be noted that embodiments of the proposed arrangement are largely evident to the person skilled in the art from the procedural aspects of the invention and are therefore to be regarded as belonging to the invention even if no express claims are directed to them.

[0018] However, it should be emphasized that preferably an induction heater for the stabilizer rod and additionally a heating device for reheating the area of ​​the stabilizer rod on both sides of the stabilizer bearing or each attached stabilizer bearing may be provided, which is also designed as an inductive or radiant heating device, which in particular includes an NIR heating device.

[0019] Furthermore, it should be noted that, in addition to the heating device for the stabilizer rod, a heating device is preferably also provided for heating at least the inner surfaces of the elastomer partial shells that contact the stabilizer rod in the assembled state. This preferably comprises a radiant heating device, in particular a NIR heating device.

[0020] Advantageously, in the proposed arrangement, at least some of the means for feeding the parts are designed as industrial robots. Depending on the specific configuration, however, belt or chain conveyors or similar known feeding devices can also be provided.

[0021] In one embodiment of the arrangement, each combination of upper and lower tool for forming a stabilizer bearing is assigned a separate press ram. The press rams can share a common drive and are controlled, in particular, by a common process control unit.

[0022] Furthermore, it should be noted that the appended claims do not provide a complete description of all parts and features of a stabilizer with integrated stabilizer bearings and its manufacture, but rather aim to identify the essential aspects of the inventive method and arrangement. In particular, steps of the thermal pretreatment and shaping of the stabilizer rod that are known per se are not explained, nor are any additional steps and arrangement components required for its complete assembly. Design and control features of the joining press(s) and feeding devices for the individual parts belonging to the inventive arrangement and used in the inventive method are also not described here, as they are known per se to those skilled in the art.

[0023] It is further pointed out that combinations of features of individual dependent claims, insofar as they are readily apparent to the person skilled in the art, are also to be regarded as lying within the scope of protection of the invention.

Claims

[1] Method for manufacturing a stabilizer with at least one integrated stabilizer bearing, in particular two integrated stabilizer bearings, comprising the steps: (a) Providing a stabilizer bar with a suitable shape and structure, (b) Providing two elastomeric partial shells per stabilizer bearing, the inner contour of which is adapted to the cross-section of the stabilizer bar in the intended mounting area, (c) Providing at least one clamp element adapted to the outer contour of the elastomer shells of the corresponding stabilizer bearing for enclosing at least the majority of the circumference of the elastomer shells, (d) Local heating of the stabilizer bar in the area of ​​the mounting of the stabilizer bearing(s) to a predetermined final temperature, (e) Inserting the clamp element and a first elastomer partial shell into an upper or lower tool and at least the second elastomer partial shell into a lower or upper tool opposite the upper or lower tool of a joining press, (f) Closing the upper and lower tools and pressing the clamp element or elements and the elastomer partial shells with the stabilizer bar between the upper and lower tools for a predetermined time and with a predetermined pressure to form a positive connection at least between the stabilizer bar and the elastomer partial shells and (g) Opening the upper and lower tooling and removing and allowing to cool the stabilizer bar with the at least one integrated stabilizer bearing, characterized by , that after step (f) or step (g) a step (g1) of reheating the stabilizer bar is carried out on both sides of the stabilizer bearing or each attached stabilizer bearing. [2] Method according to claim 1, wherein step (a) comprises providing a powder-coated stabilizer rod. [3] Method according to claim 1 or 2, wherein step (b) comprises providing rubber partial shells. [4] Method according to one of the preceding claims, wherein step (c) comprises providing two clamp elements per stabilizer bearing having a shape such that the two clamp elements together substantially completely enclose the elastomer partial shells. [5] Method according to one of claims 1 to 3, wherein in step (c) a single clamp element is provided for each stabilizer bearing and after step (f) a step (f1) of temporary external fixing of the single clamp element to the circumference of the elastomer partial shells is carried out. [6] Method according to one of the preceding claims, wherein the outer surface of the stabilizer bar is coated with an adhesion and / or polymerization agent at least in the area of ​​the attachment of the stabilizer bearing or each stabilizer bearing or the inner surfaces of the elastomer partial shells contacting the stabilizer bar in the joined state. [7] Method according to one of the preceding claims, wherein in step (d) inductive local heating is carried out by means of induction coils brought to the surface of the stabilizer rod. [8] Method according to one of the preceding claims, wherein after step (d) a step (d1) of heating at least the inner surfaces of the elastomer partial shells contacting the stabilizer rod in the joined state is carried out to a predetermined temperature. [9] Method according to claim 8, wherein step (d1) is carried out as radiative heating, in particular by means of near infrared radiation. [10] Method according to one of the preceding claims, wherein step (g1) is carried out by means of inductive heating or radiant heating, in particular by means of near infrared radiation. [11] Method according to one of the preceding claims, wherein the predetermined final temperature in step (d) and the predetermined pressing time and pressing pressure in step (f) and optionally the heating temperature of the elastomer partial shells in the optional step (d1) are predetermined in such a way that a materially bonded connection is formed between the stabilizer rod and the elastomer partial shells without any change to the microstructure of the stabilizer rod or any damage to an optional powder coating. [12] Arrangement for carrying out the procedure according to any of the preceding claims, comprising: - a heating device for locally heating a prepared stabilizer rod with a predetermined shape in the area of ​​the intended mounting of the stabilizer bearing or bearings to a predetermined final temperature, - Means for feeding the stabilizer bar to a joining press, - Feeding two elastomer partial shells per intended stabilizer bearing to the joining press, - Feeding at least one clamp element per intended stabilizer bearing to the joining press, - a joining press with an upper and a lower tool, which are shaped for inserting the clamp element and a first elastomer partial shell or for inserting at least the second elastomer partial shell, and a closing and opening mechanism and a press ram for applying a predetermined pressing pressure to the parts inserted into the upper and lower tools, - a heating device for reheating the area of ​​the stabilizer bar on both sides of the stabilizer bearing or each attached stabilizer bearing, and - Means for removing the mounted stabilizer with at least one integrated stabilizer bearing from the joining press. [13] Arrangement according to claim 12, wherein the heating device for the stabilizer rod is designed as an inductive heating device. [14] Arrangement according to claim 12 or 13, wherein a heating device is additionally provided for heating at least the inner surfaces of the elastomer partial shells which, in the joined state, touch the stabilizer rod. [15] Arrangement according to claim 14, wherein the device for heating the elastomer partial shells comprises an NIR heating device. [16] Arrangement according to one of claims 12 to 15, wherein the heating device for reheating is designed as an inductive or radiant heating device. [17] Arrangement according to one of claims 12 to 16, comprising a process control device with a control program memory in which a control program for executing the method is stored, which, when executed, controls the predetermined final temperature in step (d) as well as the predetermined pressing time and pressing pressure in step (f) and optionally the heating temperature of the elastomer partial shells in the optional step (d1) in such a way that a materially bonded connection is created between the stabilizer rod and the elastomer partial shells without any change in the microstructure of the stabilizer rod or damage to an optional powder coating. [18] Arrangement according to one of claims 12 to 17, wherein at least part of the means for feeding the parts are designed as industrial robots. [19] Arrangement according to one of claims 12 to 18, wherein each combination of upper and lower tool for forming a stabilizer bearing is assigned a separate press punch. [20] Arrangement according to one of claims 12 to 19, wherein means are provided for fixing a single clamp element to the circumference of the mounted stabilizer bearing after it has left the upper and lower tool.