Vehicle Stabilizer Eye Portion Precision Design
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Solution Overview
Problem
Conventional vehicle stabilizers face challenges in achieving high-precision fastening surfaces due to limitations in plastic working methods, leading to inaccuracies in the positional relationship between the distal end surface and through-hole of the eye portion, and difficulties in maintaining flatness and parallelization, which results in increased costs and complexity.
Innovation Solution
The vehicle stabilizer features a design with parallel first and second flat surfaces, a distal-end-side curved portion, and a hole-side curved portion, where the hole-side curved portion has a greater curvature than the distal-end-side curved portion, and specific lengths and thickness reductions, allowing for precise control of the annular reference surface and through-hole, reducing the impact of processing variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the eye portion is formed by plastic working such as upsetting, then the manufacturing process is simplified, but the manufacturing precision of the fastening surface deteriorates
Solution Approach 1:
The eye portion is divided into multiple functional zones: a flat annular reference surface for precise positioning, distal-end-side and hole-side curved portions for stress distribution, and trimmed portions for shape control. This segmentation allows each zone to perform its specific function optimally while maintaining overall manufacturing simplicity.
Solution Approach 2:
Different regions of the eye portion are given different geometric characteristics tailored to their specific functions. The flat annular reference surface provides a precise mounting interface, while the curved portions provide stress distribution and the trimmed portions provide shape control. This local differentiation of geometric quality enables high precision where needed while maintaining simple plastic working elsewhere.
2Length of moving object
If the distance from the distal end of the eye portion to the through-hole is shortened, then the compactness is improved, but the manufacturing precision of the fastening surface deteriorates
Solution Approach 1:
The flat annular reference surface is formed as an integral part of the plastic working process, establishing the precise fastening surface geometry before final trimming operations. This preliminary formation of the reference surface ensures that even in shortened eye portions, the critical fastening accuracy is achieved through the predetermined geometric features.
Solution Approach 2:
The solution moves from controlling precision solely through dimensional constraints to using geometric form features. The flat annular reference surface and curved portions create a three-dimensional geometric framework that defines the fastening precision, allowing compact eye portions to maintain accuracy through shape rather than size.
3Manufacturing precision
If finish processing such as machining is applied to the eye portion, then the manufacturing precision is improved, but the work and cost increase
Solution Approach 1:
The plastic working process itself is designed to create the necessary geometric features for precision, including the flat annular reference surface and curved portions. The material deformation during upsetting naturally forms these features, making the process self-sufficient for achieving precision without requiring additional machining operations.
Solution Approach 2:
The invention changes the approach from post-processing correction to in-process formation. By carefully controlling the plastic working parameters (pressure, temperature, tool geometry), the desired precision is achieved directly during forming. The geometric parameters of the curved portions and reference surface are optimized to self-compensate for typical plastic working variations.
Data Source
Figure 1
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Figure 4
AI summary
An annular reference surface (52) is formed around a through-hole (45) of an eye portion (21). A distal-end-side curved portion (55) is formed at a first corner portion (C1) where a first flat surface (41) intersects a distal end surface (50), on an outer side of the annular reference surface (52). The thickness of the distal-end-side curved portion (55) is reduced in a range of a length (H1) from the first flat surface (41) toward the distal end surface (50). A hole-side curved portion (60) whose thickness is reduced toward an inner surface (46) of the through-hole (45) is formed at a second corner portion (C2) where the first flat surface (41) intersects the inner surface (46), on an inner side of the annular reference surface (52). The length of the hole-side curved portion (60) is less than the length (H1) of the distal-end-side curved portion (55). The hole-side curved portion (60) is curved with a greater curvature (i.e., a smaller radius of curvature) than that of the distal-end-side curved portion (55).