Vehicle Roll-Rod Insulator Compression Tuning for NVH and R&H
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Solution Overview
Problem
Existing roll-rods for vehicles face challenges in selecting insulators that balance noise, vibration, and harshness (NVH) performance with ride & handling (R&H) performance, as these characteristics often conflict with each other, requiring frequent changes in insulator characteristics and leading to increased manufacturing costs and labor.
Innovation Solution
The roll-rod incorporates a structure with paired rear insulators, each comprising an insulator rubber portion and an insulator core portion, with through holes to accommodate a coupling member that selectively changes the compression amount of the insulators, allowing for easy adjustment to meet conflicting NVH and R&H performance requirements without the need for new molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the characteristics of insulators are changed to balance NVH performance and R&H performance, then performance requirements are satisfied, but manufacturing costs and labor increase due to needing new molds
Solution Approach 1:
The insulator is divided into a rubber portion and a core portion that can be assembled separately. The core portion is inserted into the rubber portion through a through-hole, creating a modular structure that allows independent manufacturing and assembly of the two components, thereby avoiding the need for complete remolding when characteristics need adjustment.
Solution Approach 2:
The insulator structure is made adjustable through the coupling member that can be positioned at different locations along the rod. By changing the coupling position, the compression amount of the insulator is selectively changed, allowing dynamic adjustment of insulator characteristics to satisfy different performance requirements without manufacturing new molds.
2Reliability
If insulator characteristics are adjusted to meet performance requirements, then NVH and R&H performance are satisfied, but production time increases due to mold manufacturing
Solution Approach 1:
The insulator is segmented into rubber and core portions that are manufactured separately and assembled together. This segmentation allows the rubber portion to be produced using an existing mold while the core portion is inserted afterward, eliminating the need to wait for new mold manufacturing when performance adjustments are needed.
Solution Approach 2:
The adjustable coupling member enables post-manufacturing adjustment of insulator characteristics by changing its position along the rod. This dynamic adjustment capability eliminates time-consuming remolding processes and allows rapid adaptation to different performance requirements.
3Ease of manufacture
If a single insulator structure is used, then manufacturing is simple, but it cannot simultaneously satisfy conflicting NVH and R&H performance requirements
Solution Approach 1:
The insulator is divided into a rubber portion and a core portion with different functional characteristics. The rubber portion provides damping and flexibility, while the core portion provides structural support. This segmentation allows each portion to be optimized for its specific function while maintaining manufacturing simplicity through separate production and assembly.
Solution Approach 2:
The coupling member can be positioned at different locations along the rod to selectively change the compression amount of the insulator. This dynamic adjustability enables the same insulator structure to adapt to different performance requirements, satisfying both NVH and R&H performance needs without compromising manufacturing simplicity.
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
This solution enables the roll-rod to easily secure space on a subframe and adjust insulator characteristics to satisfy both NVH and R&H performance, reducing manufacturing costs and labor by eliminating the need for separate insulator molds.
Implementation Method 1
a front insulator 40 and a rear insulator 50 made of rubber material (or synthetic resin material) are disposed side by side on the front and rear sides of the main case 30, respectively... the front insulator 40 and the rear insulator 50 elastically deform to insulate vibration
Implementation Method 2
a coupling member is inserted into the holes to fix the rear insulators in the state in which the compression amount of the insulator rubber portion is selectively changed
Data Source
AI summary
A roll-rod for a vehicle includes a rod bracket including mounted therein a front insulator to be connected to a powertrain apparatus, a first rear insulator disposed on a rod bar extending from the rod bracket and configured to reduce vibration transmitted from the outside thereof, a case bracket disposed on the rod bar and connected to a subframe, a second rear insulator disposed to face the first rear insulator with the case bracket as a boundary therebetween and configured to reduce vibration transmitted from the outside thereof, and a coupling member inserted into the rod bar and passing through the first rear insulator and the second rear insulator to be coupled thereto but configured to selectively change the compression amounts of the first rear insulator and the second rear insulator depending on coupling positions of the coupling member.