Vibration Damper Piston Rod Wedge Bracing for Lightweight Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional vibration dampers and piston rods face challenges in achieving weight and material savings while maintaining strength and continuous loading properties, leading to higher component weights, costs, and limited vibration damper performance.
Innovation Solution
A vibration damper design incorporating a piston rod with wedge element recesses and a bracing element that securely attaches the working piston using a wedge element, allowing for a non-positive connection that is adjustable and reduces friction, weight, and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional threaded connections are used to attach the working piston to the piston rod, then the connection is secure, but the component weight and material usage increase
Solution Approach 1:
The connection is divided into two functional parts: a positive connection element (protrusion) for secure attachment and a wedge element for stress distribution and friction reduction. This segmentation allows each element to be optimized independently, reducing overall material usage while maintaining connection strength.
Solution Approach 2:
The connection transitions from a rigid threaded fixation to a dynamic wedge-based system where the bracing element can adjust its position along the piston rod. This dynamic arrangement allows the connection to adapt to loading conditions, reducing stress concentrations and enabling lighter construction.
2Strength
If heavier piston rod components are used to ensure strength, then continuous loading properties are maintained, but vibration damper performance decreases and costs increase
Solution Approach 1:
Instead of uniformly increasing the entire piston rod's mass, the reinforcement is localized to specific areas where stresses occur. The wedge element and bracing element configuration provides localized strengthening exactly where needed, maintaining overall performance while minimizing weight.
Solution Approach 2:
The connection system combines different material properties and structural forms (positive connection element, wedge element, bracing element) to achieve superior strength-to-weight ratio. This composite approach allows optimization of each component's material selection based on its specific functional requirements.
3Reliability
If threaded connections are used for piston rod attachment, then the working piston is securely fixed, but manufacturing costs and machining complexity increase
Solution Approach 1:
The complex threading operation is extracted and replaced with simpler forming operations. The positive connection element and wedge element can be created through casting, forging, or additive manufacturing, eliminating the need for precise threading and reducing machining time and tooling costs.
Solution Approach 2:
The design accepts that the piston rod connection components may be replaced rather than repaired. By using simpler, more cost-effective manufacturing methods for the connection elements, the overall system becomes more economical even if component replacement is needed, reducing total cost of ownership.
4Strength
If traditional piston rod designs are used, then structural integrity is maintained, but weight savings and material efficiency are limited
Solution Approach 1:
The wedge element is pre-positioned in its recess, and the bracing element is designed to engage with the positive connection element before full loading occurs. This preliminary arrangement ensures that stress distribution is optimized from the start of loading, preventing stress concentrations that would require additional material for safety margins.
Solution Approach 2:
The design changes the geometric parameters of the connection elements to optimize material usage. By carefully designing the wedge angle, protrusion dimensions, and bracing element geometry, the structure achieves maximum strength with minimum material, improving material efficiency without compromising integrity.
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 enables lower component weights, improved strength, reduced friction, and lower manufacturing costs, with a secure and stress-free attachment of the working piston, enhancing vibration damper performance and making it more resistant to overloading.
Implementation Method 1
at least one wedge element (7, 7'), in particular at least one wedge-shaped element, and at least one bracing element (8), in particular at least one rod-like bracing element, which are configured in such a way that, in a braced state, the at least one bracing element (8) is braced to the piston rod (3) in a stress-free manner via the at least one wedge element (7, 7'), in particular in a夹紧manner, by way of the wedge effect
Data Source
AI summary
A vibration damper may include a damper tube filled at least partially with damping liquid. A piston rod is movable to and fro in the damper tube. A working piston is movable with the piston rod by way of which working piston an interior space of the damper tube is divided into two spaces. The vibration damper may have a wedge element and a bracing element, and the piston rod may have a wedge element recess for partially receiving the wedge element. The wedge element may be arranged in the at least one wedge element recess in a braced state, and the at least one bracing element may be connected to the working piston such that the bracing element braces the working piston with respect to the piston rod via the wedge element arranged in the element recess.