Vibration Damper Stop Cap Radial Spring Tongue Assembly
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Solution Overview
Problem
The existing vibration damper assembly process is complex and costly due to the need for a separate tool to achieve a uniform resilient deformation of the end cap for forming a preassembled structural unit between the stop buffer, protective tube, and end cap, requiring additional production costs.
Innovation Solution
The cap features a radially set-back spring tongue with a spreading element that is actuated during assembly, allowing the positive-locking element to engage with the protective element without the need for a specific tool, utilizing the damper tube's diameter enlargement to spread the spring tongue radially and form a positive-locking connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate tool is used to achieve uniform resilient deformation of the end cap for forming a preassembled structural unit, then the positive-locking connection between the cap and protective element can be achieved, but the assembly process becomes more complex and production costs increase
Solution Approach 1:
The cap is designed to perform its own deformation during the assembly process. When the cap is pressed onto the damper tube, the resilient spring tongues automatically deform radially outward due to the interference fit with the damper tube's outer peripheral region, eliminating the need for separate deformation tools. The cap serves both as the component being assembled and as the mechanism that deforms itself into the locked position.
Solution Approach 2:
The deformation function and assembly function are merged into a single integrated process. The act of assembling the cap onto the damper tube simultaneously performs both the deformation of the spring tongues and the formation of the positive-locking connection with the protective element, combining what were previously separate operations into one unified action.
2Reliability
If a separate tool is used to achieve uniform resilient deformation of the end cap, then the positive-locking connection can be formed, but additional production costs are incurred
Solution Approach 1:
The cap structure is self-sufficient, using its own resilient spring tongues to achieve the necessary deformation during assembly. This eliminates the need for additional specialized tools that would increase production costs, while still ensuring reliable positive-locking connection formation through the automatic radial deformation of the spring tongues during the pressing operation.
3Reliability
If the spring tongue is radially resilient to enable positive-locking connection, then the connection with protective element is achieved, but a separate working step with specialized tool is required
Solution Approach 1:
The deformation step and assembly step are merged into a single simultaneous operation. The resilient spring tongues deform radially outward during the same pressing operation that assembles the cap onto the damper tube and positions the protective element, eliminating sequential steps and reducing total assembly time while maintaining reliable positive-locking connection.
Solution Approach 2:
The useful action of deforming the spring tongues continues throughout the entire assembly process without interruption. The deformation is not a separate discrete step but occurs continuously as the cap is pressed onto the damper tube, maximizing efficiency and minimizing assembly time.
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 simplifies the assembly process and reduces costs by eliminating the requirement for additional tools, ensuring a reliable and cost-effective positive-locking connection between the cap and protective element.
Implementation Method 1
at least one resilient spring tongue, wherein disposed on the spring tongue is at least one positive-locking element for producing a positive-locking connection
Data Source
AI summary
A cap for mounting on a damper tube of a vibration damper, having an outer shell region that is cylindrical at least in sections and at least one elastic spring tongue. At least one positively locking element is arranged on the spring tongue in order to produce a positively locking connection between the cap and a protective element of the vibration damper. The at least one spring tongue has a region which, in the non-mounted state of the cap, is set back inwardly in the radial direction with respect to the outer shell region. The set-back region has a spreading element, by way of which the spring tongue is spread outwardly in the radial direction during the mounting of the cap.