Leaf Spring Holder Adaptive Molded Part Stress Reduction
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Solution Overview
Problem
The unevenness of the saddle surface in leaf spring saddles, caused by production-related deformations such as spring-back effect, manufacturing tolerances, and thermal heating, leads to stress peaks in fiber-reinforced plastic leaf springs during mounting to a vehicle axle body.
Innovation Solution
An adaptive molded part with a negative profile is used to compensate for the unevenness by increasing the contact surface between the leaf spring saddle and the adaptive layer, which is made from inelastic materials like injection molded plastic or metal, and is materially bonded to the leaf spring for stress-free support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the leaf spring saddle is manufactured using conventional processes, then production efficiency is maintained, but the saddle surface becomes uneven causing stress peaks in the leaf spring
Solution Approach 1:
The adaptive molded part is manufactured in advance with a negative profile that pre-compensates for expected saddle surface deformations. This preliminary action allows the compensation mechanism to be prepared beforehand, avoiding the need for time-consuming adjustments during assembly while maintaining high production efficiency.
Solution Approach 2:
The invention changes the geometric parameters of the support surface by introducing an adaptive molded part with a negative profile. This transforms the uniform support surface into a compensated surface that accounts for predictable deformations, thereby improving saddle surface uniformity without requiring complete re-manufacturing of the saddle.
2Manufacturing precision
If the saddle surface is made perfectly uniform, then stress peaks are eliminated, but manufacturing complexity and costs increase significantly
Solution Approach 1:
Instead of making the entire saddle surface perfectly uniform, the invention applies a localized adaptive molded part only at the support surface where contact with the leaf spring occurs. This local compensation approach eliminates stress peaks at critical points while keeping the overall structure simple and cost-effective.
Solution Approach 2:
The adaptive molded part serves as an intermediary element between the leaf spring saddle and the leaf spring. It mediates the interaction by compensating for surface irregularities, thereby eliminating stress peaks without requiring changes to the saddle structure itself, thus maintaining device simplicity.
3Reliability
If an adaptive molded part with negative profile is introduced, then contact surface is increased and stress peaks reduced, but device complexity increases
Solution Approach 1:
The invention changes the geometric parameters of the support surface by introducing an adaptive molded part with a negative profile. This transforms the uniform support surface into a compensated surface that accounts for predictable deformations, thereby improving saddle surface uniformity without requiring complete re-manufacturing of the saddle.
Solution Approach 2:
The adaptive molded part can be manufactured from composite materials or fiber-reinforced plastics that provide both the necessary geometric compensation and adequate mechanical properties. This allows the compensation function to be integrated into a single component, reducing overall device complexity while maintaining reliability.
Data Source
AI summary
The present disclosure relates to a leaf spring holder for the mounting of a leaf spring onto an axle body of a vehicle, comprising: a leaf spring saddle configured for mounting of the leaf spring, wherein the leaf spring saddle comprises a saddle surface comprising a deformation; an adaptive molded part configured to be arranged between the leaf spring saddle and the leaf spring, wherein the adaptive molded part seats on the saddle surface via a profile surface, wherein the profile surface comprises an at least partially negative profile of the deformation to increase a contact surface between the leaf spring saddle and the profile surface.