Vehicle Stabilizer Coupling Device for Overload Protection
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Solution Overview
Problem
Existing stabilizer systems in vehicles, particularly off-road vehicles, face material fatigue and potential failure due to extreme one-sided deflection, which current technologies attempt to address through increased rigidity or decoupling mechanisms but often result in undesirable effects on suspension behavior and weight.
Innovation Solution
A coupling device with two coupling portions that connect a stabilizer to a wheel suspension, featuring a locking mechanism that allows relative movement and decouples when a threshold force is exceeded, reducing torsional load on the stabilizer and preventing overload by allowing partial relaxation of the stabilizer through mechanical displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the suspension is constructed to be more rigid to reduce spring excursion, then the stabilizer is protected from extreme deflection, but the overall suspension behavior is impaired
Solution Approach 1:
The coupling device transitions from a static rigid connection to a dynamic system that adapts its stiffness based on loading conditions. The stabilizer coupling allows relative movement between the stabilizer and wheel suspension, enabling the system to be rigid under normal conditions and flexible under extreme loads, thus resolving the contradiction between reliability and adaptability
2Reliability
If stop dampers are used to limit spring excursion, then the stabilizer is protected from extreme deflection, but even-sided redirection is impaired
Solution Approach 1:
The protective function is applied locally at the stabilizer coupling point rather than globally through stop dampers. The coupling device provides overload protection specifically where needed (at the stabilizer connection) while leaving the rest of the suspension free to operate normally, including even-sided redirection movements
3Reliability
If the stabilizer is constructed in a more stable manner, then the stabilizer protects against material fatigue, but the stabilizer reacts more rigidly and becomes heavier
Solution Approach 1:
The stabilizer system is segmented into two functional parts: the stabilizer itself (which remains lightweight and flexible) and the coupling device (which provides the protective function). The coupling device includes a first coupling portion connected to the stabilizer and a second coupling portion connected to the wheel suspension, with a locking mechanism that prevents excessive loads from reaching the stabilizer, thus protecting it from material fatigue without requiring the stabilizer itself to be heavier or more rigid
4Reliability
If the stabilizer is constructed in a more stable manner, then the stabilizer protects against material fatigue, but the stabilizer reacts more rigidly even with slight deflection
Solution Approach 1:
The coupling device dynamically adjusts its stiffness characteristics. Under normal operating conditions with slight deflections, the locking mechanism remains engaged and the stabilizer responds normally. Under extreme overload conditions, the locking mechanism releases, allowing the second coupling portion to move relative to the first, thus protecting the stabilizer from material fatigue while maintaining normal responsiveness
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 coupling device effectively protects the stabilizer from overload by allowing relative movement and partial relaxation, reducing material fatigue and maintaining suspension performance without the need for sensors or actuators, while ensuring the stabilizer returns to its normal position when conditions improve.
Implementation Method 1
a locking device (18) that, in a locking position, limits a relative movement of the second coupling portion (14) with respect to the first coupling portion (11) in a first direction (R); wherein the locking device (18) is configured in a release position to release the relative movement when a first force (F1) acting between the connection locations (12, 15) exceeds a threshold value
Implementation Method 2
with a resilient element (20) that stores a disengagement force (F2) for disengaging the locking element (19) from the chamfered portion (14.3) of the flange portion (14.2)
Data Source
AI summary
The disclosure relates to a coupling device for a stabilizer of a suspension. The coupling device has a first coupling portion and a second coupling portion that is supported thereon. One coupling portion has a connection location for the stabilizer and another coupling portion has a connection location for a wheel suspension. and the coupling device also has a locking device, which, in a locking position, limits a relative movement of the second coupling portion with respect to the first coupling portion in a first direction. In order to better protect a stabilizer from overload, the locking device is configured in a release position to release the relative movement when a first force acting between the connection locations exceeds a threshold value.