Socket Assembly Deformable Wall Preload Reduces Internal Clearances
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Solution Overview
Problem
Existing socket assemblies in vehicle suspension and steering systems face reduced operating lives due to internal clearances and eccentricities between components, which can lead to adverse wear and movement, and adding extra collapsible components is not always feasible due to space constraints and increased manufacturing costs.
Innovation Solution
A socket assembly design featuring a housing with a deformable wall that preloads a spring against a backing bearing, allowing it to situate itself radially within the bore, reducing internal clearances between components, and using a fixed exit bearing with semi-spherically curved surfaces to maintain minimal clearances without additional components or space constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If internal clearances are reduced by adding an extra collapsible component, then operating life is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention removes the need for extra collapsible components by using the housing wall itself as the preloading mechanism. The deformable wall directly applies preload force to position bearings and reduce clearances, eliminating the need for separate collapsible adjustment components.
Solution Approach 2:
The housing wall serves multiple functions: it provides structural containment, acts as a preloading mechanism through deformation, and positions the bearings radially. This multi-functionality eliminates the need for separate dedicated preloading components.
2Reliability
If internal clearances are reduced by adding an extra collapsible component, then operating life is improved, but manufacturing cost increases
Solution Approach 1:
The invention eliminates the need for extra collapsible components that would increase material and assembly costs. The deformable wall approach uses existing housing material and simple deformation processes to achieve clearance reduction.
Solution Approach 2:
The invention changes the physical state of the housing wall from rigid to deformable during assembly, allowing it to apply preload force. This parameter change enables clearance control without adding expensive components.
3Manufacturing precision
If tight tolerances are specified for dimensional features, then internal clearances are minimized, but manufacturing complexity and cost increase
Solution Approach 1:
The deformable wall applies preload force during assembly to position bearings and reduce clearances before final operation. This preliminary action compensates for tolerance variations and achieves tight effective clearances without requiring tight manufacturing tolerances on all components.
Solution Approach 2:
The invention changes the wall from a rigid constraint to a deformable active element that can adjust positioning. This allows looser manufacturing tolerances on bearing fits while achieving the desired final clearance through controlled deformation.
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 design achieves reduced internal clearances and increased consistency during manufacturing, leading to a longer operating life with fewer components and no additional cost, while allowing for looser tolerances and reduced manufacturing complexity.
Implementation Method 1
A spring is positioned in the inner bore of the housing between the wall and the backing bearing and imparts a preload force against the backing bearing
Implementation Method 2
The wall at the generally closed first end of the housing is deformed to preload the spring against the backing bearing and to reduce internal clearances between components in the inner bore of the housing
Implementation Method 3
The bearings are typically either made of metal or of a hard plastic material... in sliding contact with a ball portion of the ball stud to facilitate the rotation of the ball stud relative to the housing
Data Source
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AI summary
The socket assembly includes a housing with an inner bore that extends from a wall at a closed end to an open end. A ball stud is received in the inner bore, and a shank portion of the ball stud projects out through the open end. A backing bearing is movably disposed in the inner bore. The backing bearing presents a bearing surface which is in sliding contact with a ball portion of the ball stud. An exit bearing is locked into a fixed position within the inner bore and has another bearing surface which is in sliding contact with the ball portion. A spring is positioned between the wall and the backing bearing and imparts a preload force against the backing bearing. The wall is deformed to preload the spring against the backing bearing and reduce clearances between components in the socket assembly.