Ball Joint Cover Plate Forming for One-Step Bearing Seating
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Solution Overview
Problem
Current ball joint assembly processes require multiple pressing operations to seat the internal bearing and cover plate, leading to inefficiencies and increased manufacturing costs.
Innovation Solution
A ball joint design and manufacturing method that allows for the simultaneous seating of the bearing and cover plate using a single press operation, utilizing a tool with a center punch and bearing seat to apply force and create a domed profile, enabling a one-step assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple pressing operations are used to seat the bearing and cover plate separately, then each component can be seated precisely, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines the bearing seating operation and cover plate pressing operation into a single integrated pressing operation. The press tool applies force simultaneously to both the bearing outer race and the cover plate, achieving both seating actions in one step rather than requiring separate operations for each component.
Solution Approach 2:
The press tool is designed with multi-functionality to perform both bearing seating and cover plate pressing through a single operation. The tooling setup includes features that enable simultaneous engagement with both the bearing and cover plate, allowing one device to accomplish multiple assembly tasks that traditionally required separate specialized operations.
2Manufacturing precision
If multiple pressing operations are performed, then each component can be properly seated, but the manufacturing time and labor costs increase
Solution Approach 1:
The patent merges multiple sequential pressing operations into a single simultaneous operation. By designing the press tool and assembly process to accommodate both bearing seating and cover plate pressing in one step, the total cycle time is reduced while maintaining the quality of component seating that would otherwise require multiple separate operations.
Solution Approach 2:
The method employs preliminary positioning and setup where the bearing and cover plate are arranged in their final assembly configuration before the single pressing operation. This preliminary arrangement ensures that when the press is applied, both components are correctly positioned for simultaneous seating, eliminating the need for multiple operations to achieve proper alignment and seating.
3Productivity
If a single press operation is used to seat both bearing and cover plate, then manufacturing is streamlined and productivity increases, but the tool design and process control become more complex
Solution Approach 1:
The press tool is designed with segmented or modular features that allow it to engage with both the bearing and cover plate through distinct but coordinated mechanisms. The tooling includes separate engagement features for each component that work simultaneously, dividing the complex task into manageable functional segments that can be controlled through a single pressing operation.
Solution Approach 2:
The patent employs intermediary elements or feature geometries that facilitate the simultaneous seating of both components. These intermediary features act as mediators between the press force and the two components, distributing and coordinating the applied force to achieve proper seating of both the bearing and cover plate through the single pressing operation.
Data Source
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AI summary
A ball joint (12) includes a cover plate (36) with a nested portion (48) along an outer perimeter having a nested portion thickness (60), a domed portion (52) located radially inward of the outer perimeter having a domed portion thickness (62), and a pressed portion (50) located between the nested portion (48) and the domed portion (52) having a pressed portion thickness (58). The pressed portion thickness (58) is less than the domed portion thickness (62), which during manufacture, is formed when the cover plate (36) and bearing (26) are simultaneously pressed into their final form and position. A tool can be used to press the cover plate (36) and bearing (26) in a single operation. The tool can have interchangeable components, allowing for the manufacture of differently sized ball joints.