Pneumatic Booster Assembly Using Continuous Swaging

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Solution Overview

Problem

Existing pneumatic boosters in motor vehicle braking systems face challenges in maintaining structural integrity and resistance to wrenching forces when the thickness of the metal sheet is reduced, leading to inadequate attachment between the cover and cylinder, which compromises the booster's strength and weight reduction goals.

Innovation Solution

A device employing continuous swaging over the external periphery of the booster casing using a set of rollers that alternately bend and fold the metal sheet to achieve a strong and uniform attachment between the cover and cylinder, enhancing resistance to wrenching forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the thickness of the metal sheet is reduced to decrease the weight of the booster, then the weight is reduced, but the breaking strength at the join between the cover and the cylinder is reduced

Engineering Contradiction:
Improveweight of the boosterVSAvoidbreaking strength at the join
Core Design Contradiction:
Weight of moving objectVSStrength

Solution Approach 1:

The swaging process is segmented into multiple sequential operations performed by different rollers. The first roller performs initial swaging, followed by a second roller performing additional swaging at a different location, and potentially a third roller performing final swaging. This segmentation allows the attachment to be strengthened through multiple localized deformation zones without requiring increased material thickness.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The invention implements continuous swaging by sequentially engaging multiple rollers along the periphery of the booster casing. Each roller contributes to the attachment process in sequence, creating a continuous zone of strengthened attachment around the entire periphery rather than relying on discrete spot welds or single-point attachment.

Inventive Principle:
Principle #20Continuity of useful action

2Ease of manufacture

If spot swaging is used to attach the cover and cylinder, then the attachment is simple, but the resistance to wrenching forces is insufficient when the metal sheet thickness is greatly reduced

Engineering Contradiction:
Improvesimplicity of attachment processVSAvoidresistance to wrenching forces
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The attachment process is divided into multiple sequential swaging operations by different rollers rather than relying on a single spot swaging operation. Each roller creates a localized swaged region, and the combination of these segmented operations provides comprehensive resistance to wrenching forces around the entire periphery.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Each roller applies swaging force at a specific localized position on the periphery of the booster casing. The first roller swages at one location, the second roller swages at another location, and so on. This local quality approach strengthens specific critical zones without requiring uniform thickening of the entire metal sheet.

Inventive Principle:
Principle #3Local quality

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 continuous swaging method provides improved resistance to wrenching forces and allows for a lightweight pneumatic booster with reduced metal sheet thickness while maintaining structural integrity and strength, ensuring secure attachment between the cover and cylinder.

Implementation Method 1

The rollers, when they pass, fold one end of a metal sheet forming the wall of the cylinder around an end of a metal sheet forming the wall of the cover

Methodology Applied
Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS7950128B2Method for assembling a pneumatic booster
Publication Date: 2011.05.31 ROBERT BOSCH GMBH
  • US7950128B2 patent drawing
  • US7950128B2 patent drawing
  • US7950128B2 patent drawing

AI summary

A device (100) for assembling a pneumatic booster (200) wherein a cover (203) of the booster is housed in a support (101) and a cylindrical cap (104) whose internal volume (107) is greater than a volume of a cylinder (206) of the booster, covers the cylinder placed on the cover. A gearing element (110) of the device rotates two sets of rollers (109A and 109B) about the booster and an eccentric (118) controlled by the gearing element allows an oscillating movement of the rollers against a wall of the booster. The swaging is achieved by alternately applying the rollers (109A) and (109B) and an angle of attack (114A) of the first rollers is greater than an angle of attack (114B) of the second rollers.