Chassis Housing Welding with Inclined Surfaces

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Solution Overview

Problem

Existing methods for producing chassis components with integrated ball joint housings face issues such as precise manufacturing requirements, qualitative disadvantages in welded connections, and corrosion problems due to coating removal, especially in laser welding processes.

Innovation Solution

The method involves shaping at least one contacting surface as an inclined surface to ensure linear contact during resistance welding, which creates a material connection without additional welding material, and includes design features like conical cross-sections for self-centering and countersinks to compensate for manufacturing deviations and prevent crevice corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser welding is used to join the housing to the structural component, then welding speed and automation are improved, but the coating must be removed in the welding area which causes corrosion problems and additional production steps

Engineering Contradiction:

Improvewelding speedVSAvoidcorrosion risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces laser welding with resistance welding (capacitor discharge welding or medium-frequency welding). This substitution eliminates the need to remove coatings before welding, as resistance welding can directly weld through the coating without causing corrosion issues. The mechanical welding process is replaced by an electrical resistance-based process that is more tolerant of surface coatings.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the welding parameters by using resistance welding instead of laser welding. This parameter change allows the welding process to accommodate the presence of coatings on the housing and structural component without requiring coating removal, thereby preventing corrosion while maintaining welding effectiveness.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the receiving opening is made precisely fitted to the housing geometry, then manufacturing precision is improved, but manufacturing deviations cannot be compensated and assembly reliability decreases

Engineering Contradiction:

Improvereceiving opening dimensionVSAvoidassembly reliability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent introduces asymmetry by making the receiving opening slightly smaller than the housing geometry. This intentional dimensional asymmetry creates a press fit that ensures reliable contact between the housing and structural component, compensating for manufacturing deviations and ensuring consistent welding conditions.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent applies a pressing force before welding to ensure full contact between the housing and structural component. This preliminary action of pressing the components together eliminates gaps and ensures uniform contact, compensating for any manufacturing variations and creating optimal conditions for welding.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If the contacting surfaces are made flat and parallel, then manufacturing is simplified, but insufficient contact area occurs preventing uniform welding current density

Engineering Contradiction:

Improvesurface preparationVSAvoidwelding uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent uses inclined surfaces (chamfers) on the contacting surfaces instead of flat parallel surfaces. This geometric modification creates a line contact between the housing and structural component, which ensures comprehensive contact area and uniform distribution of welding current density during resistance welding.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 approach results in a robust, reproducible welding process that can transmit high forces, maintains corrosion protection, and avoids crevice corrosion by ensuring full contact and uniform welding conditions, suitable for series production.

Implementation Method 1

The welding is carried out by resistance welding, in particular capacitor discharge welding or medium-frequency welding

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The welding is carried out by resistance welding, in particular capacitor discharge welding or medium-frequency welding

Methodology Applied

Scientific EffectCapacitor discharge: Capacitance

Data Source

PatentEP3157769B1Method for producing a chassis component

Publication Date: 2019.06.26 ZF FRIEDRICHSHAFEN AG

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AI summary

A method for producing a chassis component (1), comprising a housing (5) which is connected to a structural component (3) by means of a weld (7), wherein a receiving opening (19) is introduced into the structural component (3) and the housing (5) is pushed into the receiving opening (19), wherein a surface on the housing side and a surface on the structural component side touch, wherein at least one of the two touching surfaces is in the form of an oblique surface (41, 31, 47) in relation to the other of the two surfaces, and therefore there is line contact between the two surfaces prior to the welding. Alternatively, the receiving opening (19) in the structural component (3) can be formed with an undersize in relation to the housing geometry which is pushed into the receiving opening (19).