Stabilizer Bar Intermediate Bushing for Tolerance Compensation
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Solution Overview
Problem
Existing stabilizer bar mounting systems face challenges in accurately positioning thrust flanges across varying manufacturing tolerances, leading to potential interference with rotation and inadequate lateral movement inhibition.
Innovation Solution
The introduction of an intermediate bushing with a locating collar and resilient bushings that limit axial movement in multiple directions, allowing for precise positioning and secure attachment to the vehicle frame while allowing for rotation, and incorporating a 'free floating' second bushing for alignment with frame mounting holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thrust flanges are fixedly secured to the center section to inhibit lateral movement, then lateral movement inhibition is improved, but positioning accuracy across manufacturing tolerances deteriorates
Solution Approach 1:
The patent introduces a movable collar as an intermediary component between the bushing and the center section. This collar can slide axially along the center section to accommodate variations in component lengths and mounting hole positions, while still providing the necessary lateral support through its engagement with the bushing. The movable collar acts as a mediator that absorbs dimensional variations without compromising lateral movement inhibition.
Solution Approach 2:
The collar is designed to be movable rather than fixed, allowing it to dynamically adjust its position along the center section axis. This dynamic capability enables the system to adapt to manufacturing tolerances in the lengths of the center section and arms, as well as variations in mounting hole positions, while maintaining reliable lateral movement inhibition throughout the range of motion.
2Ease of operation
If thrust flanges are positioned to allow rotation of the center section, then rotation freedom is improved, but lateral movement inhibition deteriorates
Solution Approach 1:
The movable collar serves as an intermediary that decouples the rotation function from the lateral support function. The collar's engagement with the bushing provides lateral support, while its ability to slide axially and rotate independently allows the center section to rotate freely without compromising the lateral inhibition provided by the bushing-c collar interface.
3Manufacturing precision
If multiple components are assembled to achieve precise positioning, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the movable collar component: it provides lateral support, allows axial adjustment, enables rotation, and accommodates manufacturing tolerances. By merging these functions into a single movable component rather than requiring multiple separate adjustment mechanisms, the system achieves precise positioning without proportionally increasing complexity.
Solution Approach 2:
The mounting system is segmented into distinct functional components: the fixed bushing provides lateral support, while the movable collar handles axial positioning and rotation. This segmentation allows each component to be optimized for its specific function, achieving overall positioning accuracy without requiring all components to be highly complex.
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 configuration enhances the accuracy and adaptability of stabilizer bar mounting, ensuring effective body roll reduction during turns across different manufacturing tolerances and preventing contamination ingress.
Implementation Method 1
The first bushing is at least partially formed of a resilient material... The locating collar limits movement of the first bushing along an axis of the center section
Data Source
AI summary
A suspension system having a stabilizer bar assembly with a stabilizer bar structure, an intermediate bushing and a resilient bushing. The stabilizer bar structure includes a center section to which the intermediate bushing is coupled. The resilient bushing is mounted on the intermediate bushing. The intermediate bushing limits relative axial movement of the resilient bushing in along the center section in a first direction and a second direction opposite the first direction. A method for forming a stabilizer bar assembly is also provided.