Vehicle Roll Rod Assembly Without Bolts for Lighter Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing roll rod assembly methods using bolts and nuts are costly, heavy, and require manual assembly, with the added issue of bolts loosening due to load and resonance.
Innovation Solution
A roll rod assembly structure that eliminates the use of bolts and nuts by integrating an end plate and rod bracket through press-fitting and riveting, allowing for automatic assembly and reducing weight and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolts and nuts are used to assemble the end plate and rod bracket, then the connection strength and reliability are improved, but the weight and manufacturing cost increase
Solution Approach 1:
The end plate and rod bracket are merged into a single integrated component through press-fitting and riveting processes. The end plate is press-fitted into the rod bracket, and rivets are inserted to secure the connection, eliminating the need for separate bolts and nuts. This merging of components reduces the number of fastening elements, thereby reducing weight while maintaining connection strength.
2Reliability
If bolts and nuts are used to assemble the end plate and rod bracket, then the connection reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The end plate and rod bracket are merged into a single integrated component through press-fitting and riveting processes. The end plate is press-fitted into the rod bracket, and rivets are inserted to secure the connection, eliminating the need for separate bolts and nuts. This merging of components reduces the number of fastening elements, thereby reducing weight while maintaining connection strength.
3Manufacturing precision
If manual assembly is used for the roll rod components, then the assembly precision and quality control are improved, but the productivity decreases
Solution Approach 1:
The press-fitting and riveting processes are designed to be self-aligning and self-securing. The end plate is press-fitted into the rod bracket with precise dimensional tolerances that ensure proper alignment, and rivets are automatically inserted and deformed to secure the connection. This self-service mechanism eliminates the need for manual adjustment and quality control interventions, enabling automatic assembly while maintaining precision.
4Strength
If bolts are used to secure the end plate, then the connection strength is improved, but the complexity of preventing bolt loosening under load increases
Solution Approach 1:
The bolt and nut fastening system is extracted and removed from the assembly. Instead of using bolts that require anti-loosening mechanisms, the design uses press-fitting to create a interference fit between the end plate and rod bracket, supplemented by rivets that permanently secure the connection. This extraction of the bolt system eliminates the need for complex anti-loosening features while maintaining connection strength.
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 new assembly structure reduces costs and weight by eliminating bolts and nuts, enables automatic assembly improving productivity, and prevents bolt loosening issues due to load and resonance.
Implementation Method 1
a fastening bar press-fitted and fixed into a rear portion of the rod bracket
Implementation Method 2
press-fitted and fixed
Implementation Method 3
a rivet portion provided on the front portion of the fastening bar... when the anti-rotation protrusions are inserted into the protrusion insertion grooves, the rivet portion is riveted
Data Source
AI summary
An embodiment roll rod includes a rod bracket, a front insulator coupled to a front portion of the rod bracket, an end plate including a fastening bar press-fitted and fixed into a rear portion of the rod bracket, a rear insulator coupled to the fastening bar and disposed between the end plate and the rod bracket, and a casing bracket coupled to an outer portion of the rear insulator.