Two-Part Ball-Joint Socket for Tool-Free Wiper Linkage Assembly
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Solution Overview
Problem
Existing methods for assembling ball-joint assemblies on-site require significant manual effort and tools for assembly, and existing systems lack flexibility in positioning components, necessitating complex tooling and increased effort on vehicle production lines.
Innovation Solution
A two-part socket configuration for the ball-joint assembly, where one part is overmolded on the connecting rod and the other part is fitted to the crankpin, allowing assembly without specialized tools and ensuring resilient joint formation without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-piece socket is used for the ball-joint assembly, then the joint structure is simple, but assembly requires specialized stamping press tools and significant manual effort on vehicle production lines
Solution Approach 1:
The socket is divided into two separate parts: a first part that is overmolded on the connecting rod and a second part that is fitted on the crankpin. This segmentation allows each part to be manufactured and assembled independently, eliminating the need for specialized stamping press tools and reducing assembly effort on vehicle production lines while maintaining structural integrity through the resilient connection between parts.
2Ease of operation
If a plastic socket is fitted to the crankpin with metallic edges, then assembly is simplified, but the plastic socket is damaged by forces at the junction
Solution Approach 1:
The first part of the socket acts as an intermediary element between the connecting rod and the second part. It is overmolded on the connecting rod to create a resilient connection that absorbs and distributes forces, preventing direct contact between metallic edges and the plastic socket, thereby avoiding damage while maintaining assembly simplicity.
3Ease of operation
If a two-part socket is used for the ball-joint assembly, then assembly effort is reduced and tool usage is minimized, but the joint between parts must be sufficiently resilient
Solution Approach 1:
The material properties and geometric parameters of the two socket parts are optimized to ensure sufficient resilience. The first part is overmolded with specific dimensional tolerances and material characteristics that allow it to deform elastically under load, while the second part is designed with corresponding features that maintain a reliable resilient connection, enabling easy assembly without tools while ensuring joint reliability.
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
Facilitates easy assembly of ball-joint assemblies on vehicle production lines with reduced effort, minimizing tool usage and preventing damage to plastic components, while effectively transferring forces between the connecting rod and crank.
Implementation Method 1
a first part being overmolded on the opening disposed at an end of the connecting rod
Implementation Method 2
the second part comprising a plurality of elastic fingers forming first lateral projections
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A ball-joint assembly (34, 36, 38) of a crank (30, 32) and a connecting rod (26, 28) of a windshield wiper module, comprising a crankpin (40) fixed to the crank (30, 32) and a ball-joint housing comprising a socket (42) being arranged to receive the crankpin (40), said socket (42) being fixed in an opening (46) of an end of the connecting rod (26, 28), wherein the socket (42) is made in two parts (48, 50) assembled one with the other with a first part (48) being overmolded on the opening (46) of the end of the connecting rod (26, 28) and a second part (50) being fitted on the crankpin (40), said first part (48) having a hole (49) configured to receive the second part (50).