Ball Assembly Swaging and Composite Design
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Solution Overview
Problem
Existing swing training aids fail to withstand the high forces of impact applied by athletes over an extended period, leading to device failure during prolonged use.
Innovation Solution
A ball assembly apparatus comprising a wire rope, ball stud, and connector sleeve with swaging connections and soft metal components, along with a coating, designed to withstand repeated high forces, featuring rounded edges and hollow tunnels for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional swing training aids are used, then they provide basic training functionality, but they fail to withstand high impact forces over extended periods
Solution Approach 1:
The patent employs a composite construction combining a hard metal wire rope with soft metal ball stud and connector sleeve components. This composite material approach allows the hard wire rope to withstand high impact forces while the soft metal components provide deformation absorption and stress distribution, enabling the assembly to endure over 1500 hits from professional athletes
Solution Approach 2:
The hollow tunnel design in the ball stud and connector sleeve, along with the rounded edges of the openings, creates built-in cushioning zones that absorb impact energy before it reaches critical stress points. This preliminary cushioning mechanism prevents catastrophic failure under repeated high-force impacts
2Reliability
If the ball connection is designed to withstand high forces, then durability improves, but the complexity of the connection structure increases
Solution Approach 1:
The connection structure is divided into distinct functional segments: the wire rope for force transmission, the ball stud for ball retention, the hollow tunnel for structural reinforcement and cushioning, and the connector sleeve for attachment. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity
Solution Approach 2:
Different regions of the connection structure have different material properties - the wire rope is hard metal for strength, while the ball stud and connector sleeve openings are soft metal for cushioning. This local quality differentiation provides impact resistance without requiring the entire structure to be complex
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
The ball assembly apparatus maintains integrity and longevity, capable of withstanding over 1500 hits by professional athletes, with expected longevity exceeding 2000 hits, and potentially doubling to 4000 hits for less forceful athletes.
Implementation Method 1
A swaging connection joins a first end of the wire rope and the first end of the ball stud and a second end of the wire rope and the first end of the connector sleeve
Data Source
AI summary
A ball assembly for a swing trainer that withstands repeated hits with forces applied by professional athletes. The ball assembly comprises a ball, a wire rope, a ball stud swaged to one end of the wire rope and a connector sleeve swaged to the other end of the wire rope. A whole is drilled through the exact center of the ball and wire threaded therethrough. After the ball stud and connector sleeves are swaged to the ends of the wire rope, the ball stud is pressed into the hole in the ball. The wire rope may be coated to extend life.