Ball Joint with Integrated Pivot Shaft for Third Element Coupling
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Solution Overview
Problem
Existing ball joints restrict design freedom by not allowing a third mechanical element to be coupled freely near the pivot center, requiring additional assembly steps that increase manufacturing costs.
Innovation Solution
A ball joint with a pivot shaft integrated during casting, allowing a third mechanical element to be coupled independently near the pivot center of the first and second mechanical elements, reducing assembly complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a third mechanical element is coupled to one of the existing mechanical elements, then the coupling is achieved, but the pivot center cannot be positioned near the ball portion and design freedom is restricted
Solution Approach 1:
The holder is segmented to include multiple independent coupling portions: a fixing portion for the second mechanical element and a pivot shaft for the third mechanical element. This segmentation allows each coupling to have its own pivot center, enabling the third mechanical element to be positioned near the ball portion while maintaining independent rotation axes.
Solution Approach 2:
The holder is designed as a multi-functional component that simultaneously provides: (1) support for the ball portion, (2) a fixing portion for coupling the second mechanical element, and (3) a pivot shaft for coupling the third mechanical element. This multi-functionality eliminates the need for additional separate coupling mechanisms.
2Adaptability or versatility
If the fixing portion is machined to form a coupling portion, then the third mechanical element can be coupled, but the number of work man-hours and manufacturing cost increase
Solution Approach 1:
The pivot shaft is integrated with the holder through casting, merging two components into a single monolithic structure. This eliminates the need for separate drilling and assembly operations that would be required if the coupling portion were machined into the holder, thereby reducing manufacturing cost and complexity.
Solution Approach 2:
The pivot shaft is pre-formed as an integral part of the holder during the casting process, before any assembly operations. This preliminary formation of the coupling structure eliminates subsequent machining and assembly steps, reducing work man-hours and manufacturing cost.
3Adaptability or versatility
If drilling and pin driving are performed to form the coupling portion, then the third mechanical element can be coupled, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The pivot shaft and holder are merged into a single cast component, eliminating the need for separate drilling and pin driving operations. This integration simplifies the assembly process and improves productivity by reducing the number of assembly steps.
Solution Approach 2:
The casting process itself creates the integrated pivot shaft structure, making the holder self-sufficient as a complete coupling mechanism. No additional assembly operations are needed to create the coupling function, as the structure is self-formed during manufacturing.
Data Source
AI summary
Provided is a ball joint capable of coupling a third mechanical element in a freely pivotable manner near a pivot center of a first mechanical element and a second mechanical element coupled to each other in a freely pivotable manner. The ball joint includes: a ball stud including: a shaft member configured to allow a first mechanical element to be coupled thereto; and a ball portion formed at a distal end of the shaft member; a holder including a fixing port ion configured to allow a second mechanical element to be coupled thereto, the holder being formed through casting with the ball portion being set as a core to cover a maximum diameter portion of the ball portion, the holder being configured to couple the first mechanical element and the second mechanical element in a freely pivotable manner with the ball portion defining a pivot center; and a pivot shaft that protrudes out of the holder in a direction of intersecting with the shaft member of the ball stud to define a second pivot center independently of the ball portion, and to serve as a coupling portion for a third mechanical element, the pivot shaft being integrated with the holder at the time of the casting of the holder.