Integrated Nut Bracket for Vehicle Suspension Rigidity
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Solution Overview
Problem
Weld nuts used in mechanical coupling of vehicle components, particularly in suspension systems, face durability concerns due to welding defects and lack of rigidity under external loads, making them unsuitable for high-load applications.
Innovation Solution
A nut integrated with a bracket is formed through a process involving pre-drawing, forging, and cam upsetting, where a beading portion is created on a plate material between a punch and a die, and the nut is pierced and forged to increase rigidity, with a protruding end supporting the bracket's ends to enhance joint rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If weld nuts are used for mechanical coupling of vehicle components, then the coupling function is achieved, but durability is reduced due to welding defects and corrosion
Solution Approach 1:
The patent merges the bracket and nut into a single integrally formed component made from plate material. The bracket body and nut are formed as one piece through stamping and forming processes, eliminating the separate welding operation. This integration removes the welding defects and corrosion issues associated with joining separate components, while maintaining the mechanical coupling function.
2Strength
If weld nuts are used in suspension system components, then the coupling function is achieved, but rigidity at input points is insufficient under external loads
Solution Approach 1:
By integrating the bracket and nut into a single monolithic structure, the patent creates continuous material flow and eliminates weak weld joints. The integral construction ensures uniform stress distribution and maintains rigidity throughout the component, particularly at critical input points where loads are applied in suspension systems.
Solution Approach 2:
The patent implements local quality enhancement by forming a protruding end on the nut that extends beyond the bracket surface. This localized structural feature increases rigidity at the critical input point where external loads are applied, while maintaining the overall coupling function of the component.
3Reliability
If a nut is integrally formed with a bracket through multiple processing steps, then rigidity and durability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations (stamping, forming, piercing, and thread formation) into an integrated multi-step process that creates the bracket-nut assembly in one continuous manufacturing flow. While the process involves multiple steps, they are sequentially integrated without requiring separate welding or assembly operations, ultimately simplifying the overall manufacturing complexity compared to traditional methods.
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 integrated nut and bracket design enhances rigidity at input points, improving structural durability and addressing the limitations of weld nuts in high-load applications.
Implementation Method 1
forming a beading portion by processing the processing cross section through multiple steps, and piercing a center of the beading portion; a forging operation of forming a pipe portion having a tube shape by gradually widening an aperture in the beading portion
Data Source
AI summary
A nut integrated with a bracket and a method of manufacturing the same is provided. The method includes a pre-drawing operation that forms a reference aperture and a processing cross section in the plate material supplied between the punch and the die, forming a beading portion and piercing a center of the beading portion. A forging operation forms a pipe portion having a tube shape and processes an exterior circumferential surface of the pipe portion. A precision forging process adjusts dimensions of the pipe portion formed in the tube shape, forms a protruding end that extends on a tip surface of the pipe portion and compresses the pipe portion to remove residual burrs on a surface. A post-processing operation cuts the processing cross section to a final product shape, and forms a threaded tap on an interior circumferential surface of the pipe portion.