Forked Wearable Shim Assembly for Fast Suspension Replacement
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Solution Overview
Problem
Current wearable shims for suspension systems require complex disassembly for replacement, leading to significant downtime and increased costs due to lost productivity, as they wear out over time and do not allow for fast swapping.
Innovation Solution
A forked wearable shim design with a breakaway slot and fastening mechanism that allows for quick replacement without disassembling the suspension system, featuring a shim body with planar surfaces, alignment and fastening openings, and a forked end for secure attachment and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional shims are used in suspension systems, then the shims can control wear and maintain alignment, but the shims require complex disassembly of the entire suspension system for replacement, leading to significant downtime
Solution Approach 1:
The shim is divided into a modular assembly consisting of a shim body with a forked end and a retainer component. This segmentation allows the shim to be replaced as a complete unit without disassembling the suspension system, as the entire shim assembly can be removed and installed by simply detaching the retainer from the pin joint.
Solution Approach 2:
The retainer component is designed to be easily extracted from the pin joint, allowing the shim assembly to be removed without affecting other suspension components. The retainer can be quickly taken out by removing fasteners, enabling fast replacement while leaving the rest of the suspension system intact.
2Ease of repair
If traditional shims are used in suspension systems, then the shims provide wear control, but technicians must remove various interconnected parts such as control arms and struts to access the shims
Solution Approach 1:
The shim maintenance system is segmented into the shim assembly and the retainer component. This allows maintenance personnel to access and replace the shim by only dealing with the retainer and fasteners, without needing to disconnect control arms, struts, or other suspension components. The segmented design isolates the maintenance task to a specific location at the pin joint.
Solution Approach 2:
The retainer component can be extracted from the pin joint independently of the suspension system's other components. This extraction capability enables technicians to perform shim maintenance by simply removing the retainer and fasteners, eliminating the need to handle interconnected parts like control arms and struts.
3Reliability
If traditional shims are used in suspension systems, then the shims maintain proper alignment, but the replacement process requires careful handling to avoid damaging adjacent components
Solution Approach 1:
The shim assembly is segmented with a dedicated retainer component that houses the alignment-critical forked end. This segmentation protects the precision-forged forked end from damage during replacement, as the retainer acts as a protective carrier that can be easily removed and reinstalled without exposing the fragile forked end to handling risks.
Solution Approach 2:
The retainer component can be extracted as a complete unit containing the forked end, allowing the precision components to be removed and installed without separate handling. This extraction method eliminates the need for careful manual handling of the forked end itself, reducing the risk of damage to adjacent components during the replacement process.
4Strength
If standard steel shims are used for suspension designs, then the shims provide structural support, but they do not allow fast swapping when worn
Solution Approach 1:
The shim is designed as a segmented assembly with a strong precision-forged forked end for structural support and a separate retainer component for easy replacement. This segmentation maintains the strength requirements of the load-bearing forked end while enabling fast swapping of the entire assembly without affecting the structural integrity of the suspension system.
Solution Approach 2:
The retainer component can be quickly extracted from the pin joint, allowing the worn shim assembly to be replaced with a new one in minimal time. This extraction capability enables fast swapping that restores equipment productivity quickly, while the precision-forged forked end of the new shim immediately provides the required structural support.
Data Source
AI summary
In an embodiment, a forked wearable shim for use in a suspension system, comprising: a shim body including a first planar surface and a second planar surface; a shank portion, the shank portion having an alignment opening extending through the body from the first planar surface through the second planar surface and a fastening opening extending through the body from the first planar surface through the second planar surface located between an end of the shank portion and the alignment opening; a forked-shaped second end having a first prong extending away from the shank portion and a second prong opposite the first prong and extending away from the shank portion; and a first breakaway slot and a second breakaway slot.