Sleeve-Integrated Member with Double-Layered Flange
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current sleeve-integrated members for brake pedal devices lack sufficient rigidity and strength, especially at the leading end, and are difficult to manufacture efficiently, as they often rely on welding or pressing methods that compromise workability and structural integrity.
Innovation Solution
A sleeve-integrated member with a waist part formed by drawing and a leading end flange portion having a double-layered structure, manufactured through a process involving drawing, crushing, and piercing steps to create a continuous material flow and increased wall thickness, ensuring enhanced rigidity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sleeve is formed by pressing with drawing formation, then the workability and manufacturing ease are improved, but the leading end of the sleeve becomes thin-walled and insufficient in strength and rigidity
Solution Approach 1:
The sleeve is designed with non-uniform wall thickness: the intermediate portion has a first wall thickness formed by drawing, while the leading end portion has a second wall thickness that is greater than the first. This local quality variation ensures that the leading end, which experiences higher stress during brake operation, has sufficient strength and rigidity, while the intermediate portions maintain adequate structural integrity with thinner walls for weight reduction and material efficiency.
2Strength
If multiple sleeves are attached to the substrate by welding, then the structural integrity is improved, but the workability decreases and manufacturing time increases
Solution Approach 1:
Multiple sleeves are integrated into a single substrate through a unified pressing and drawing formation process rather than attaching separate sleeves individually. This merging of the substrate and multiple sleeves into a single integrated component eliminates the need for multiple welding operations, significantly reducing manufacturing time and improving productivity while maintaining structural integrity through continuous material flow.
Solution Approach 2:
The sleeves are pre-formed with appropriate shapes and positions on the substrate through drawing formation before final assembly. This preliminary shaping allows the sleeves to be ready for integration without requiring time-consuming post-formation adjustments or attachments, streamlining the manufacturing process.
3Adaptability or versatility
If the spacer and endplate are separate parts, then the assembly flexibility is improved, but the attachment process becomes troublesome and time-consuming
Solution Approach 1:
The spacer (sleeve) and endplate (substrate) are merged into a single integrated member where the sleeve is formed directly from the substrate through pressing and drawing. This integration eliminates the need for separate attachment steps, reducing assembly time and complexity while maintaining the functional benefits of having a spaced relationship between the brake pedal device and dash panel.
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 provides a sleeve-integrated member with improved rigidity and strength throughout, including the leading end, and simplifies the manufacturing process by using pressing techniques, ensuring the member can withstand heavy loads and is easier to produce.
Implementation Method 1
a protrusion part raised so as to have an axis line orthogonal to a planar surface of the substrate before opening of the through-holes
Implementation Method 2
a crushing step for crushing the protrusion part formed at the drawing step to the predetermined height
Data Source
AI summary
The invention is characterized in that, when protrusion parts 30 are raised from a substrate W and the protrusion parts 30 are formed into spacers 12 with a predetermined outer diameter D and height H, the protrusion parts 30 are temporarily formed so as to have a diameter larger than a predetermined outer diameter D and a height larger than a predetermined height H, and the protrusion parts 30 are crushed, and leading end portions 30b of the protrusion parts 30 are protruded in a radially outward direction so as to have a double-layered structure, and then through-holes 35 are opened at the leading end portions 30b. Accordingly, the leading end portions 30b have strength due to a double-layered structure, and side portions 30a also have high strength due to contraction by pressing, whereby the sleeve-integrated member includes the entirely high-strength spacers 12.