Dual Roller Rail Assembly NVH Reduction
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Solution Overview
Problem
Existing vehicle seating assembly roller systems experience rattle, noise, and vibration due to the interaction between rollers and rails, often requiring secondary axles to mitigate these issues, which complicates design and manufacturing.
Innovation Solution
A single axis dual roller assembly with first and second rollers of different diameters positioned on axles extending from an anchor, where the first roller contacts the rail's step and the second roller contacts the upper wall, utilizing spacers to maintain alignment and reduce friction, thereby eliminating the need for secondary axles and minimizing noise and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional roller systems are used with rails, then seating translation is enabled, but rattle, noise, and vibration occur due to roller-rail interaction
Solution Approach 1:
The roller is divided into two separate rollers mounted on a common axle: a first roller that contacts the rail surface and a second roller that contacts the step. This segmentation allows each roller to be optimized for its specific contact function, reducing unwanted interaction and NVH while maintaining translation capability.
Solution Approach 2:
A spacer is introduced as an intermediary element between the first and second rollers on the axle. The spacer maintains precise spacing and alignment between the two rollers, ensuring proper contact geometry with the rail and step while isolating the rollers from direct mechanical interference with each other, thereby reducing noise and vibration.
2Object-generated harmful factors
If secondary axles are added to mitigate rattle and noise, then NVH is reduced, but design and manufacturing complexity increases
Solution Approach 1:
The patent combines the functions of two rollers and their supporting axles into a single integrated axle assembly. The first and second rollers are mounted on the same axle, eliminating the need for separate secondary axles while still achieving NVH reduction through the dual-roller configuration and spacer isolation.
Solution Approach 2:
The single axle serves multiple functions: it supports both the first roller (for rail contact) and the second roller (for step contact), and provides a mounting structure for the spacer. This multi-functional design reduces component count and simplifies manufacturing while achieving the same NVH mitigation效果.
3Reliability
If dual rollers of different diameters are used, then proper contact with rail surfaces is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The spacer acts as a precision intermediary that establishes and maintains the correct spacing and alignment between the first and second rollers. By fixing the relative positions of the two rollers with different diameters, the spacer ensures that each roller contacts its designated surface (rail or step) at the correct location, achieving reliable contact geometry while simplifying manufacturing through a standardized spacing component.
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 reduces noise, vibration, and harshness (NVH) by ensuring proper contact between rollers and rail surfaces, enhancing the compactness and manufacturing simplicity of the roller assembly while maintaining smooth operation of vehicle seating assemblies.
Implementation Method 1
A first roller may be positioned on the axle. A second roller may be positioned on the axle. The second roller may be positioned between the first roller and the anchor... the first roller contacts the rail's step and the second roller contacts the upper wall, utilizing spacers to maintain alignment and reduce friction
Data Source
AI summary
A roller assembly for a vehicle seating assembly is provided. The roller assembly includes an anchor rotatably coupled with a vehicle seating support. An axle extends from the anchor. A first roller is positioned on the axle. A second roller is positioned on the axle and between the first roller and the anchor. A spacer is positioned on the axle and flush with the second roller.