Shock Absorber Knuckle Bracket Welding for High-Load Strength
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Solution Overview
Problem
The existing shock absorbers used in strut suspensions face challenges in maintaining sufficient joining strength between the outer shell and the knuckle bracket, especially when subjected to increased vehicle weights and repeated high loads, due to potential gaps formed during the welding process.
Innovation Solution
The shock absorber design incorporates a knuckle bracket with a C-shaped welded portion that is welded along the outer circumference of the outer shell, excluding the two circumferential ends of the C-shaped surface, to enhance the joining strength and tolerance against high loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the knuckle bracket is welded to the outer shell using the top end surfaces of the reinforcing portions and holding portion as the welding surface, then the joining strength is sufficient for current vehicle weights, but the joining strength becomes insufficient when subjected to increased vehicle weights and repeated high loads due to springback causing gaps between the welding surface and outer shell
Solution Approach 1:
The knuckle bracket is pre-clamped to the outer shell before welding to prevent gap formation during the welding process. This preliminary clamping action counteracts the springback effect that would otherwise occur during welding, ensuring continuous contact between the welding surface and outer shell throughout the welding operation, thereby maintaining reliable welded joints under repeated high loads
Solution Approach 2:
The welding parameters are optimized to account for the springback behavior of the knuckle bracket. By adjusting welding current, speed, and sequence, the process compensates for the dimensional changes that occur during welding, preventing gap formation and ensuring consistent weld quality even when the bracket attempts to return to its original shape
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 configuration improves the joining strength between the knuckle bracket and the outer shell, enabling the shock absorber to withstand repeated applications of high loads more effectively than conventional designs.
Implementation Method 1
a knuckle bracket attached, by welding, to an outer circumference of a bottom end of the outer shell
Data Source
AI summary
A shock absorber according to the present invention includes: a shock absorber main body having an outer shell and a rod; and a knuckle bracket attached to an outer circumference of the bottom end of the outer shell. The knuckle bracket includes: a holding portion having a cylindrical shape with a C-shaped cross section, and that holds the outer circumference of the outer shell; a pair of attachment portions extending radially outwards, and in parallel with each other, from respective circumferential ends of the holding portion; and reinforcing portions formed by bending top ends of the attachment portions in directions approaching each other; and a C-shaped welded portion having a C-shaped surface that is formed by top ends of the reinforcing portions and a top end of the holding portion, the C-shaped welded portion being formed by welding the C-shaped surface to the outer shell, across a range from a position spaced from one circumferential end of the C-shaped surface, traversing across an upper part of a rear side of the holding portion, to the other circumferential end of the C-shaped surface.