Sheet Metal Hitch Assembly Eliminates Bending
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hitch and draw bar manufacturing processes are costly, space-consuming, and require additional equipment and inventory control due to the need for bending and forming of flat stock, which can lead to tolerance issues and rust buildup in vehicle receivers.
Innovation Solution
A ball mount and method of manufacturing using an assembly of flat components cut or stamped from sheet metal, assembled without forming or bending, and welded together to form a rigid unit, which can be used alone or with a stacked receiver also made from flat components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hollow tube or solid bar stock is used to manufacture hitches, then structural strength is achieved, but storage and shipping costs increase and inventory control becomes more complex
Solution Approach 1:
The hitch is divided into multiple flat components (sides, bridge plates, ball mount plate) that are manufactured separately and assembled together. This segmentation allows each component to be produced from simple flat sheet metal, eliminating the need to store and manage complex hollow tubes or solid bars, thereby reducing inventory control complexity while maintaining structural integrity through the assembled configuration.
2Shape
If flat stock is bent or formed to offset the ball vertically, then the desired geometry is achieved, but additional equipment and process complexity are required
Solution Approach 1:
Instead of bending flat stock in three dimensions to achieve the ball offset geometry, the invention uses multiple flat components arranged in a stacked configuration. The vertical offset is achieved by stacking components of different thicknesses (side components with first thickness, ball mount plate with greater second thickness) rather than forming curved surfaces, eliminating the need for bending equipment and simplifying the manufacturing process.
3Ease of operation
If hollow tube closely matches the shape of the receiver, then fit is improved, but rust buildup occurs in the receiver
Solution Approach 1:
The hitch assembly is segmented into multiple flat components with gaps between them, creating a non-solid structure that prevents continuous contact with the receiver interior. This segmentation allows moisture and rust to drain through the gaps rather than accumulating, eliminating the rust buildup problem while maintaining proper fit through the overall configuration of the stacked components.
4Shape
If bending and forming processes are used, then complex shapes are achieved, but tolerance issues arise requiring additional controls
Solution Approach 1:
The invention changes the manufacturing parameters from bending and forming operations to simple cutting and stamping of flat sheet metal. These parameter changes eliminate the tolerance issues associated with plastic deformation, as cutting and stamping processes produce more consistent dimensions. The complex geometry is achieved through the assembly of multiple components with precise cut dimensions rather than through forming operations.
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 reduces manufacturing costs and complexity by eliminating the need for bending and forming, while also preventing rust buildup in vehicle receivers, thus improving the efficiency and reliability of hitch and draw bar production.
Implementation Method 1
Once assembled, the components are welded together to form a rigid unit.
Data Source
AI summary
A ball mount is formed from a plurality of components that are only cut from flat sheet metal. The components are two identical sides, two identical bridge plates, and one ball mount plate that are assembled and then welded together to form a rigid assembly. The sides have a plurality of slots to receive complementary tabs located on the bridge plates, along with apertures to locate the ball mount plate. The bridge plates have lateral edges that set the distance between the sides. A stacked receiver can be used with the ball mount that is also formed without bending. The stacked receiver has sides and partition plates that are cut from sheet metal, along with a length of tubing that are assembled and then welded together.