Air Spring Fastening Using Forged Plug-In Connection
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Solution Overview
Problem
Existing air spring fastening systems for commercial vehicles require complex rework and additional reinforcement, making them costly and inefficient, especially when attaching a plastic rolling piston to a handlebar.
Innovation Solution
A plug-in connection system using an insertion peg and shaft, where the peg is formed from a bent end of the handlebar, allowing for easy assembly and improved force distribution, eliminating the need for subsequent machining and additional reinforcement, and enabling rotary and pendulum movements for better air spring characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screw connection is used to fasten the air spring to the handlebar, then the air spring can be securely attached, but complex rework of the link is required including drilling mounting holes, face milling of the bearing surface, and welding work
Solution Approach 1:
The mounting holes and bearing surface are prepared during the initial forging process of the handlebar rather than as subsequent rework operations. The holes are formed as part of the forging die set, eliminating the need for separate drilling and machining operations.
Solution Approach 2:
Multiple operations (drilling, face milling, welding) are combined into a single forging process. The handlebar is forged with pre-formed mounting holes and prepared bearing surfaces in one manufacturing step, integrating what would otherwise be separate sequential operations.
2Strength
If a steel reinforcement plate is added to connect a plastic rolling piston, then the connection strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The handlebar is forged from a composite material structure that combines plastic and metal properties. The plastic handlebar body provides corrosion resistance and weight reduction, while embedded metal reinforcement elements provide the necessary strength for connecting the rolling piston, eliminating the need for separate steel reinforcement plates.
Solution Approach 2:
Metal reinforcement elements are embedded within the plastic handlebar structure to serve as intermediaries that transfer loads between the plastic body and the rolling piston connection points, providing strength without requiring external reinforcement plates.
3Reliability
If the force application point is arranged in the area of the piston crown, then the rolling piston can be connected to the chassis, but additional reinforcement means such as plates or enlarged contact surface are required
Solution Approach 1:
The force application is distributed across a three-dimensional forged structure rather than concentrated on a two-dimensional surface. The handlebar's forged geometry creates a volumetric load distribution that eliminates the need for additional reinforcement plates or enlarged contact surfaces.
4Manufacturing precision
If subsequent machining operations are performed on the handlebar, then the mounting holes and bearing surfaces can be created, but the manufacturing time and cost increase
Solution Approach 1:
The mounting holes and bearing surfaces are formed during the initial forging operation rather than as subsequent machining steps. The forging die set includes features that create precisely positioned holes and surfaces with the required geometric accuracy directly during forming.
Solution Approach 2:
The forging process itself creates the mounting features without requiring separate machining operations. The high pressure and temperature of forging enable direct formation of complex geometries including threaded holes and precision bearing surfaces that would otherwise require multiple machining steps.
Data Source
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AI summary
An air spring attachment system for motor vehicles. The air spring attachment system includes at least one air spring and at least one link for the suspension of a wheel on a chassis. The air spring attachment system also includes a plug-in connection connecting the air spring to the link.