Dog-bone Rear Roll Rod Extrusion Plate Design
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Solution Overview
Problem
The existing methods for manufacturing rear roll rods, particularly for the three-point support method in vehicles, are costly and time-consuming due to the use of traditional squeeze processes, which result in high material waste and increased costs, while also being prone to damage from external factors and high loads during sudden unintended acceleration evaluations.
Innovation Solution
The dog-bone type rear roll rod is manufactured using an extrusion method, with an extrusion plate fitted in a sliding manner to increase the cross-sectional area of the rod's end portion, allowing for uniform load dispersion to the front rubber and reducing manufacturing time and costs, and featuring a through hole for the inner pipe and '⊏' shaped end portions for secure fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the squeeze process method is used to manufacture the rod portion, then strength and rigidity are ensured, but manufacturing time increases and costs increase
Solution Approach 1:
The patent changes the manufacturing process parameter from squeeze process to extrusion process. The extrusion process uses a different forming mechanism where material is pushed through a die to create the rod portion, which reduces manufacturing time and costs while still achieving the required strength and rigidity through proper die design and process control
Solution Approach 2:
The patent adopts a more cost-effective manufacturing approach by using extrusion instead of squeeze process. The extrusion process allows for continuous production with less material waste and lower tooling costs, making it a more economical solution for manufacturing the rod portion of the roll rod
2Strength
If the squeeze process method is used to manufacture the rod portion, then strength and rigidity are ensured, but manufacturing costs increase
Solution Approach 1:
The patent changes the manufacturing process parameter from squeeze process to extrusion process. The extrusion process uses a different forming mechanism where material is pushed through a die to create the rod portion, which reduces manufacturing time and costs while still achieving the required strength and rigidity through proper die design and process control
Solution Approach 2:
The patent adopts a more cost-effective manufacturing approach by using extrusion instead of squeeze process. The extrusion process allows for continuous production with less material waste and lower tooling costs, making it a more economical solution for manufacturing the rod portion of the roll rod
3Shape
If the rod portion is made with predetermined length and positioned at lowest end, then structural requirements are met, but damage risk from external factors increases
Solution Approach 1:
The patent applies composite material construction by combining the rod portion (made by extrusion) with the extrusion plate and fastening members to create a composite structure. This composite design enhances the overall strength and damage resistance of the rod assembly, allowing it to better withstand external factors while maintaining the required structural configuration
Solution Approach 2:
The patent incorporates design features that provide beforehand cushioning against potential damage. The extrusion plate with through hole and the fastening members create a reinforced structure that anticipates and mitigates the effects of external factors before damage can occur to the rod portion
4Stress or pressure
If the extrusion plate is press-fitted between the rod and front rubber, then load dispersion is improved, but assembly complexity increases
Solution Approach 1:
The patent merges the load distribution function into the extrusion plate structure itself. By press-fitting the extrusion plate between the rod and front rubber, the plate serves as both a structural component and a load distribution element, eliminating the need for separate load distribution mechanisms and simplifying the overall assembly
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 reduces manufacturing time and costs, enhances load distribution, and improves the structural integrity of the rear roll rod, making it more cost-efficient and robust while minimizing material waste.
Implementation Method 1
an extrusion plate which has a through hole formed such that the inner pipe penetrates a center of the extrusion plate, has a width length greater than a width length of the rod, and is press-fitted between the rod and the front rubber
Data Source
AI summary
Disclosed is a dog-bone type rear roll rod in which a body bracket, which is fixed to a vehicle body, and front and rear rubbers, which are disposed at front and rear sides of the body bracket, respectively, are connected together through an inner pipe and fastened to a rod by means of a fastening member, the dog-bone type rear roll rod including: an extrusion plate which has a through hole formed such that the inner pipe penetrates a center of the extrusion plate, has a width length greater than a width length of the rod, and is press-fitted between the rod and the front rubber.