Damping Valve Control Pot Fixation by Plastic Deformation
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Solution Overview
Problem
Existing control arrangements for frequency-dependent damping valve devices in vibration dampers lack high functional reliability and secure fixation during the manufacturing and assembly processes.
Innovation Solution
A control arrangement with a guide bush featuring a cutout for positive engagement with the control pot, allowing for plastic deformation to secure the control pot axially and radially, ensuring a permanent and cost-effective fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control pot is fixed to the guide bush using conventional methods, then the assembly can be manufactured, but the fixation is not secure enough during manufacturing and assembly processes
Solution Approach 1:
The guide bush is divided into two functional regions: a trough region for radial positioning and a cutout region for axial securing. This segmentation allows the fixation system to address both radial and axial stability requirements separately, achieving secure fixation during manufacturing and assembly processes.
Solution Approach 2:
The trough is formed in advance on the guide bush before assembly, creating a pre-positioned radial stop. This preliminary action ensures that the control pot is correctly positioned radially before the final axial securing operation, preventing misalignment during subsequent manufacturing steps.
2Ease of operation
If the control pot is secured axially and radially to the guide bush, then the handling and functionality are improved, but the structural complexity increases
Solution Approach 1:
The trough and cutout features are integrated directly into the guide bush structure, combining the positioning and securing functions into a single component. This merging approach improves handling and functionality without requiring separate fixation components, thus avoiding excessive structural complexity.
Solution Approach 2:
The deformed pot base material acts as an intermediary element that fills the cutout and creates a positive engagement between the control pot and guide bush. This intermediary mechanism provides secure axial and radial fixation through material deformation rather than complex mechanical fasteners.
3Reliability
If a positive engagement connection is formed by plastic deformation of the pot base, then secure fixation is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The pot base material undergoes a parameter change from elastic to plastic state during the deformation process. This parameter change allows the material to permanently set in the cutout, creating a reliable positive engagement connection that secures the control pot axially and radially to the guide bush.
Solution Approach 2:
The plastic deformation process replaces complex mechanical fastening systems with a simpler deformation-based fixation. By applying controlled mechanical forces to deform the pot base into the cutout, the system achieves secure fixation without requiring screws, clips, or other complex mechanical fasteners.
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
The solution enhances the functional reliability and handling of the control arrangement by ensuring secure fixation throughout the manufacturing and assembly process, improving the overall functionality of the vibration damper.
Implementation Method 1
The pot base has a deformation portion which is produced by the plastic deformation, the deformation portion having a trough which partially receives the guide bush
Data Source
AI summary
A control arrangement for a frequency-dependent damping valve of a vibration damper having a control pot with a cylindrical pot wall and a pot base adjoining the pot wall, a control piston arranged axially displaceable in the control pot between first and second end positions. The pot base has a deformation portion produced by plastic deformation that defines the first end position. The control piston is slidingly guided at a guide bush. The deformation portion defines a trough in which the guide bush is received by a first axial end and a spring unit supported at the control piston acts on the control piston with a spring force. The guide bush has a cutout at the first axial end arranged in the trough and in which a base material of the control base is displaced by plastic deformation to form a positive engagement connection.