Chassis Ball Joint Housing Joining for Stability
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Solution Overview
Problem
Existing chassis assemblies struggle to transmit higher forces and moments from the ball joint to the structural component effectively, leading to instability and potential failure under load conditions.
Innovation Solution
A method for producing a chassis assembly where the ball joint housing is circumferentially connected to the structural component's through-opening edge and inner wall sections using material-locking joining without additional material, creating a stable connection that absorbs tilting and bending moments, and optionally reinforced with additional material for localized load peaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the ball joint housing is connected only to the edge section of the through-opening, then the manufacturing process is simple, but the stability and force transmission capability are insufficient
Solution Approach 1:
The connection structure is segmented into multiple independent connection points: one at the edge section and additional ones at inner wall sections spaced apart from the edge. This segmentation allows the ball joint housing to be stabilized at multiple locations without requiring a complex continuous connection, resolving the contradiction between stability and simplicity.
Solution Approach 2:
Additional connections are created at specific local positions (inner wall sections spaced apart from the edge) rather than uniformly across the entire through-opening. This localized approach provides enhanced stability where needed while maintaining manufacturing simplicity in other areas.
2Strength
If conventional joining methods are used, then the manufacturing process is simple, but the force and moment transmission capability is limited
Solution Approach 1:
The ball joint housing is inserted into the through-opening before the final joining process. This preliminary positioning allows for precise alignment and ensures that the housing is properly seated against the edge section before applying the joining force, thereby enhancing force transmission capability while maintaining manufacturing simplicity.
Solution Approach 2:
The edge section of the through-opening acts as an intermediary element that transfers forces and moments between the ball joint housing and the structural component. By designing the connection to utilize this intermediary, the system achieves enhanced force transmission without requiring complex direct connections.
3Force
If the ball joint housing is stabilized with multiple connection points, then force transmission is improved, but the risk of distortion and corrosion increases
Solution Approach 1:
Instead of creating a continuous connection around the entire through-opening, the invention uses a partial connection approach with discrete connection points at the edge section and spaced inner wall sections. This partial action provides sufficient force transmission capability while leaving gaps that reduce distortion risks and allow for corrosion protection.
Solution Approach 2:
Rather than preventing corrosion through continuous sealing, the invention inverts the approach by using spaced connections that inherently allow for ventilation and corrosion protection. The gaps between connection points serve to reduce corrosion risk while the edge section connection provides the necessary stabilization.
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
This method enhances the stability of the ball joint housing within the structural component, enabling effective transmission of forces and moments while minimizing distortion and corrosion risks, and allows for flexible reinforcement based on vehicle models without additional plant investments.
Implementation Method 1
The outer circumference of the ball joint housing is connected circumferentially to a section of the through-opening at the edge by material joining without additional material
Data Source
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AI summary
The invention provides a method for manufacturing a chassis assembly (1) comprising a structural component (3) with a through-opening (5) into which a ball joint housing (7) is inserted. The outer circumference of the ball joint housing (7) is connected circumferentially to an edge-side section (9) of the through-opening (5) by a material-bonded joining without additional material (11). According to the invention, the ball joint housing (7) is additionally connected circumferentially to at least one inner wall section (13) of the through-opening (5), spaced apart from the edge-side section (9), also by a material-bonded joining without additional material (15). The invention further relates to a chassis assembly (1) comprising a structural component (3) and a ball joint housing (7), which chassis assembly (1) is manufactured according to this method, wherein the chassis assembly is designed as a flange joint (1) or as a multi-point linkage.