Shock Absorber Spring Seat Assembly Without Jig Interference
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Solution Overview
Problem
The challenge in manufacturing damping force adjustable shock absorbers is the interference of a rotation restricting jig for the spring seat with the control valve or bracket due to a short axial distance between the control valve and the spring seat, making it difficult to press-fit the spring seat without being restricted by the damping force adjustment mechanism or bracket.
Innovation Solution
A method of manufacturing a shock absorber that includes a fastening step to join the damping unit and actuating unit, followed by a spring-seat fixing step to secure the spring seat to the outer cylinder, using a spring seat fixing jig that positions the spring seat without interference from the damping force adjustment mechanism or bracket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the spring seat is fixed to the outer cylinder before fastening the damping unit and actuating unit, then the spring seat can be positioned, but the rotation restricting jig for the spring seat interferes with the control valve or bracket due to short axial distance
Solution Approach 1:
The damping unit and actuating unit are fastened together in advance before the spring seat is fixed to the outer cylinder. This preliminary fastening action eliminates the need for a rotation restricting jig during spring seat installation, as the spring seat can be freely positioned without interfering with other components. The sequence is reversed from conventional methods to avoid the interference problem.
2Length of moving object
If the axial distance between control valve and spring seat is short (30 mm or less), then the shock absorber compactness is improved, but the fastening jig cannot be brought closer to the case accommodating the damping force adjustment mechanism
Solution Approach 1:
The fastening of the damping unit and actuating unit is performed as a preliminary action before installing the spring seat. This allows the fastening jig to access the components without obstruction, even when the axial distance is short. By completing the fastening operation first, the subsequent spring seat installation does not require additional clearance that would compromise compactness.
3Manufacturing precision
If the spring seat is press-fitted over the shock absorber main body with rotation restriction, then the spring seat position is controlled, but the rotation restricting jig interferes with the control valve or bracket
Solution Approach 1:
The rotation restricting jig is completely removed from the manufacturing process by changing the sequence of operations. Instead of using a jig to restrict rotation during spring seat installation, the method allows free positioning of the spring seat during press-fitting. The damping unit and actuating unit are already fastened together beforehand, eliminating the need for rotation restriction during spring seat installation.
Data Source
AI summary
A damping unit and an actuating unit of a damping force adjustment mechanism are inserted into a case provided to a side portion of an outer tube (outer cylinder). After the damping unit and the actuating unit are fastened together, a shock absorber main body with an upper end (another end) of a piston rod facing down is placed in a spring seat fixing jig, and a spring seat is fixed (press-fitted) over the shock absorber main body. A spring seat support portion of the spring seat fixing jig is not arranged between the damping force adjustment mechanism or a bracket and the spring seat. Thus, the spring seat can be fixed (press-fitted) over the shock absorber main body (outer cylinder) without being restricted by an arrangement of the damping force adjustment mechanism or the bracket.