Shock Absorber Knuckle Bracket Structure for Stable Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing shock absorbers face issues with inconsistent welding quality between the knuckle bracket and the outer shell due to dimensional tolerances, leading to backlash and unstable attachment.
Innovation Solution
The shock absorber design incorporates a knuckle bracket with clamping pieces that curve along the outer shell, attachment pieces extending radially, and a connecting piece, allowing stable contact and welding without excessive gaps, ensuring consistent support and improved welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the knuckle bracket and outer shell are molded according to design dimensions with curved surfaces having the same curvature, then the abutment situation should be tight, but dimensional tolerance causes the abutment situation to change for each product, resulting in unstable welding quality
Solution Approach 1:
The knuckle bracket is divided into a pair of separate clamping pieces that can independently contact the outer shell. This segmentation allows each clamping piece to adapt to dimensional variations in the outer shell, ensuring consistent abutment tightness and welding quality across different products despite manufacturing tolerances.
Solution Approach 2:
The clamping pieces are designed with specific local geometric features including a curved inner peripheral surface with a radius of curvature larger than the outer shell's outer diameter, and an abutting surface positioned at a specific location. This local quality design ensures reliable abutment and welding at critical points while accommodating overall dimensional variations.
2Manufacturing precision
If the inner peripheral surface of the tube abutting portion and the side surface of the connecting portion are curved surfaces with the same curvature as the outer shell, then they should closely abut on the outer periphery, but backlash occurs between the knuckle bracket and outer shell due to dimensional tolerance
Solution Approach 1:
By segmenting the knuckle bracket into separate clamping pieces, the design eliminates backlash caused by dimensional tolerances. Each clamping piece can independently maintain contact with the outer shell, preventing gaps and backlash that would occur with a single monolithic bracket structure.
Solution Approach 2:
The clamping pieces incorporate curved surfaces with specific radius of curvature relationships. The inner peripheral surface has a larger radius than the outer shell's outer diameter, creating a deliberate curvature mismatch that ensures continuous contact and eliminates backlash while accommodating manufacturing variations.
3Stability of the object's composition
If the knuckle bracket uses curved tube abutting portions that abut on the outer periphery of the outer shell, then the structure should be stable, but the welding quality varies for each product and is not stable
Solution Approach 1:
Segmenting the bracket into separate clamping pieces maintains structural stability through distributed contact points while ensuring welding quality consistency. Each clamping piece can be precisely positioned and welded to the outer shell at standardized locations, eliminating the variability that occurs with monolithic bracket designs.
Solution Approach 2:
The clamping pieces are designed with pre-configured abutting surfaces and contact points that ensure proper positioning before welding. This preliminary geometric configuration guarantees consistent welding conditions for each product, eliminating variability in welding quality while maintaining structural stability.
Data Source
AI summary
A shock absorber according to the present embodiment includes a shock absorber main body having a cylindrical outer shell and a rod movably inserted into the outer shell, and a knuckle bracket attached to an outer periphery of a lower end of the outer shell, in which the knuckle bracket includes a pair of clamping pieces that are curved along an outer periphery of the outer shell and clamp the outer shell, a pair of attachment pieces that extend in a radial direction of the outer shell from the ends in a circumferential direction of the respective clamping pieces and face each other, and a connecting piece that connects ends of the attachment pieces, a width between the tip ends in the circumferential direction of the inner peripheral surfaces of the respective clamping pieces is larger than the outer diameter of the outer shell, and the proximal end side than the tip ends in the circumferential direction of the inner peripheral surfaces of the respective clamping pieces abuts on the outer periphery of the outer shell.