Shock Absorber Top Cap Assembly for Variable Piston Rod Diameters
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Solution Overview
Problem
Conventional shock absorbers require different inner plates and caps with varying hole diameters to fit different piston rod diameters, increasing manufacturing costs and inventory complexity.
Innovation Solution
A top cap assembly with first and second locking members, each with a passage and ridge design, allows for adjustable fitment by replacing only these members, ensuring stable radial restriction of the piston rod without needing cap and inner plate replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different inner plates and caps with varying hole diameters are prepared to fit different piston rod diameters, then the adaptability to different shock absorber types is improved, but the manufacturing cost and inventory pressure increase
Solution Approach 1:
The locking member is designed with a universal structure that can accommodate multiple piston rod diameters. The passage in the locking member can be adjusted or configured to match different diameter requirements, allowing a single locking member design to serve multiple shock absorber types rather than requiring dedicated locking members for each diameter specification.
Solution Approach 2:
The invention changes the parameter of the locking member's passage diameter to adapt to different piston rod diameters. By modifying the passage dimensions within the locking member while keeping the overall component structure the same, the system can fit various piston rod sizes without requiring completely different inner plates and caps.
2Adaptability or versatility
If different inner plates and caps with varying hole diameters are prepared to fit different piston rod diameters, then the adaptability to different shock absorber types is improved, but the manufacturing cost increases
Solution Approach 1:
The locking member is designed with a universal structure that can accommodate multiple piston rod diameters. The passage in the locking member can be adjusted or configured to match different diameter requirements, allowing a single locking member design to serve multiple shock absorber types rather than requiring dedicated locking members for each diameter specification.
Solution Approach 2:
The invention changes the parameter of the locking member's passage diameter to adapt to different piston rod diameters. By modifying the passage dimensions within the locking member while keeping the overall component structure the same, the system can fit various piston rod sizes without requiring completely different inner plates and caps.
3Ease of operation
If the piston rod is not properly restricted in the radial direction, then the ease of assembly is improved, but the stability of the piston rod movement deteriorates causing noise and unstable movement
Solution Approach 1:
The locking member introduces localized radial restriction features at specific positions within the assembly. The passage and its configuration provide targeted radial constraint where needed, while allowing free axial movement. This localized quality approach ensures stability without compromising the overall ease of assembly.
Data Source
AI summary
A top cap assembly for a shock absorber includes a cap which has a first locking member connected to the center thereof, and an inner plate which has a second locking member connected to the center thereof. A first section of a piston rod extends through the first passage of the first locking member and is restricted by the first ridge of the first passage. A second section of the piston rod extends through the second passage of the second locking member and is restricted by the second ridge of the second passage. When installing the top cap assembly to different shock absorbers with different diameters, only the first locking member and the second locking member need to be replaced, and the cap and the inner plate do not need to be replaced.