Multi-Piece Spring Perch for Shear-Resistant Coilover Joints
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Solution Overview
Problem
Conventional one-piece spring perches in coilover shocks are weak at the connection between the lower shaft and loop, leading to shearing under lateral forces, which can disengage the shaft from the loop.
Innovation Solution
A multi-piece spring perch design comprising a pair of half members with apertures and a U-shaped member, secured by bolts, strengthens the connection between the rod and U-shaped member, preventing shearing under lateral loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece spring perch is used, then the structure is simple and easy to manufacture, but the connection between the lower shaft and loop is weak and prone to shearing under lateral forces
Solution Approach 1:
The spring perch is divided into multiple pieces: a lower perch portion with a bore for the shaft, an upper perch portion with a slot for the spring, and a connecting portion with threading. This segmentation allows each part to be optimized for its specific function while collectively providing enhanced strength against lateral forces compared to a one-piece design.
2Reliability
If the spring perch is designed to strengthen the shaft-loop connection, then resistance to lateral forces improves, but the manufacturing complexity increases
Solution Approach 1:
By segmenting the spring perch into distinct portions (lower perch, upper perch, connecting portion), each can be manufactured separately using standard machining operations, then assembled together. This maintains manufacturing ease while achieving the reliability needed to resist shearing forces at the critical shaft-loop connection.
Solution Approach 2:
The separate perch portions are connected through threading and fastening mechanisms, merging them into a unified structure that provides enhanced reliability. The connecting portion with its threading allows for secure assembly that strengthens the overall shaft-loop connection while maintaining ease of manufacture through modular construction.
3Strength
If a multi-piece spring perch with bolts is used, then the structural integrity is enhanced, but the assembly complexity increases
Solution Approach 1:
The spring perch is segmented into portions that can be assembled in a logical sequence: the lower perch is first attached to the shaft, then the connecting portion is threaded onto the lower perch, and finally the upper perch is secured. This segmented approach enhances structural integrity while keeping the assembly process straightforward through clear assembly steps.
Solution Approach 2:
The lower perch portion is pre-attached to the shaft before assembling the rest of the spring perch components. This preliminary action simplifies the overall assembly process by establishing a stable base first, then adding subsequent components in a systematic manner, thereby maintaining ease of operation while achieving high structural integrity.
Data Source
AI summary
A multi-piece spring perch for a coilover shock is disclosed including a pair of half members. The coilover shock includes a rod, a coil spring mounted about the rod and a U-shaped member secured to a lower end of the rod. The multi-piece spring perch is mounted about the rod and the U-shaped member to receive an end of the coil spring, strengthening the connection between the rod and the U-shaped member.