Air Spring Clamping Ring Assembly Without Welded Bolts
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Solution Overview
Problem
Existing clamping ring designs for air springs require high precision welding, consume significant energy, and are prone to deformation and breakage due to inaccurate bolt positioning, leading to potential damage and loss of function.
Innovation Solution
Replace welding bolts with press bolts and use expansion nuts/washers to ensure precise axial symmetry and secure attachment, eliminating gaps and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding bolts are used to attach the clamping ring to the air spring cover, then the connection can be made, but high precision welding is required which increases manufacturing complexity and cost
Solution Approach 1:
The patent replaces the welding process with a mechanical pressing process. Press bolts are pressed into holes in the clamping ring and air spring cover, eliminating the need for welding operations. This substitution removes the requirement for high-precision welding while maintaining connection reliability through the press-fit mechanical joint.
Solution Approach 2:
The patent introduces press bolts as an intermediary element between the clamping ring and air spring cover. These press bolts serve as mediators that create a secure mechanical connection without requiring direct welding between the main components, thereby reducing manufacturing precision requirements.
2Reliability
If welding bolts are used to attach the clamping ring, then the connection can be made, but significant energy is consumed during the welding process
Solution Approach 1:
The patent replaces the energy-intensive welding process with a mechanical pressing operation. Press bolts are installed by pressing them into place, which consumes significantly less energy than welding while achieving comparable or superior connection strength through the expansion and friction fit of the press bolts.
3Ease of operation
If welding bolts are used with large air gaps, then assembly is easier, but deformation of the clamping ring bottom occurs during mounting
Solution Approach 1:
The patent replaces welding with a pressing mechanism that inherently maintains component alignment. The press bolts are pressed through aligned holes, ensuring proper positioning without the need for large air gaps or post-assembly deformation correction, thus maintaining clamping ring stability while facilitating assembly.
4Productivity
If welding bolts are used, then the air spring can be assembled, but the welding process is technologically complex and time-consuming
Solution Approach 1:
The patent replaces complex welding operations with simple mechanical pressing of bolts into place. This substitution eliminates the need for welding equipment, skill, and process control, thereby reducing device complexity and significantly increasing assembly speed and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures robust and reliable air spring connections by maintaining precise alignment and preventing damage to the rubber bellows, enhancing safety and functionality under stress and vibration.
Implementation Method 1
The press bolts (6) are provided with expansion nuts (8), the upper surface of which is level with the plane O which connects the tops (13) of the side walls (12) of the clamping ring (1)
Data Source
Figure 1~2b
Figure 3~4
AI summary
The invention relates to an air spring clamping mechanism comprising a clamping ring (1) in the form of a steel moulding with a projection on the inner edge of the ring (1) for holding a rubber bellows (4), wherein the outer edge of the clamping ring (1) is provided with a side wall (12) having a top (13) on which an air spring cover (3) of the air spring rests. The clamping ring (1) has in the lower part a bottom (11) which is provided with at least one hole (14) for a press bolt (6), a head (61) of the bolt (6) being pressed into the lower wall of the bottom (11) of the clamping ring (1) so that so that the head (61) does not protrude above the surface of this bottom wall of the bottom (11) and at the same time the head (61) and the adjacent part of the bottom (11) are smooth without sharp edges or burrs. The press bolt (6) is provided with an expansion nut (8) the whole or the uppermost surface of which passes through the plane (O), which connects the tops (13) of the side walls (12) of the clamping ring (1). The press bolt (6) is fitted with an air spring cover (3) which fits over the tops (13) of the side walls of the clamping ring (1) and rests with its lower face on the expansion nut (8) or the uppermost part thereof.