Ball Joint with Disc Spring for Wear Compensation
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Solution Overview
Problem
Ball joints in automotive suspension systems face wear issues between spherical surfaces, leading to clearance changes and potential overstressing of components, which reduces their cycle life and alignment accuracy.
Innovation Solution
A ball joint design incorporating a housing with a disc spring and annular recesses to maintain close clearance between spherical surfaces, using a disc spring to preload bearings and prevent overstressing by limiting axial movement and distributing compressive forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball joint uses grease to reduce wear between spherical surfaces, then wear is reduced, but clearance between surfaces eventually increases due to wear
Solution Approach 1:
The ball joint incorporates a spring-loaded bearing that dynamically adjusts the clearance between spherical surfaces. As wear occurs and the ball end diameter decreases, the spring automatically compresses less, allowing the bearing to move closer to the ball end and maintain optimal clearance without requiring precision manufacturing tolerances
Solution Approach 2:
The invention changes the static clearance parameter into a dynamic parameter that automatically adjusts based on wear. The spring force and bearing position are designed to vary with wear progression, transforming a precision manufacturing problem into a self-adjusting system
2Manufacturing precision
If ball joint components are designed with tight clearances, then alignment accuracy is maintained, but components are prone to overstressing
Solution Approach 1:
The spring-loaded bearing provides beforehand cushioning by maintaining a controlled gap between the ball end and housing. This gap acts as a cushion that absorbs shock loads and prevents direct impact stresses, allowing the use of tighter clearances for alignment accuracy without risking component overstressing
3Duration of action of stationary object
If ball joints operate with wear compensation mechanisms, then cycle life is extended, but device complexity increases
Solution Approach 1:
The spring-loaded bearing creates a self-service wear compensation mechanism that automatically adjusts to wear without external intervention. The spring force and bearing mobility work together to self-regulate the clearance, extending cycle life through a relatively simple mechanism rather than complex active control systems
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 design extends the cycle life of ball joints by maintaining close tolerances and preventing overstressing, reducing wear and vibration, and ensuring proper alignment during use.
Implementation Method 1
a first disc spring disposed in the first disc annular recess, the first disc annular recess laterally restraining at least one of: an outer circular edge of the first disc spring; and an inner circular edge of the first disc spring, during compression of the first disc spring
Implementation Method 2
a peripheral annular shoulder adjacent the first disc annular recess axially limiting axial movement, between the outer surface of the first bearing; and one of: the inner surface of the retention plate; and the inward surface of the seat end of the housing, thereby limiting compression of the first disc spring
Data Source
AI summary
A ball joint comprising: a housing having an inner cavity defined inward of a seat end, a side wall and a closure end having an opening, an edge about the opening in an assembly position extending upwardly; a ball stud having: a lower ball end with an outer convex spherical surface, a middle portion, and a connector end; a first bearing, slidably housed within the cavity, having an inner concave spherical surface; a retention plate, housed within the cavity inward of the edge about the opening, wherein the edge of the opening extends inwardly engaging an outer surface of the retention plate in a closed position; and a first disc annular recess in at least one of: an outward surface of the first bearing; and an inward surface of the retention plate.