Chassis Suspension Eccentric Stop Tab Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing chassis suspension components face issues with crack formation, high production costs, and weakened structures due to slotted perforations or additional weld-on elements for creating eccentric stops, which also risk material detachment and corrosion.
Innovation Solution
A chassis suspension component with a tab formed from the base material, folded to create parallel stop faces surrounding a slot, eliminating the need for additional elements and reducing production costs, while preventing crack formation and ensuring stable support for eccentric discs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If slotted perforations are used to create the stop for the eccentric disc, then the stop function is provided, but there is a risk of crack formation or crack propagation in the base material and the stop function may be lost due to compression during bolt tightening
Solution Approach 1:
The base material is segmented by introducing a groove that divides the material into two regions separated by a bridge structure. This segmentation allows the eccentric disc to be reliably stopped against the bridge without compromising the overall structural integrity of the component.
Solution Approach 2:
The groove creates a localized region with different mechanical properties - the bridge structure has reduced cross-section specifically at the stop location, while the rest of the base material maintains its original strength. This local modification provides the stop function without weakening the entire component.
2Reliability
If an additional weld-on element is used to create the stop, then the stop function is provided, but additional material costs and substantial process costs are incurred due to the additional production step
Solution Approach 1:
The stop function is merged with the base material itself through the groove and bridge structure, eliminating the need for separate weld-on elements. The stop is created as an integral part of the base material, combining the stop function with the existing component structure.
Solution Approach 2:
The unnecessary additional element is extracted from the design, leaving only the essential groove feature in the base material. This extraction removes the complexity of welding operations while maintaining the stop function through the simplified groove-bridge structure.
3Ease of manufacture
If an additional weld-on element is used to create the stop, then the stop function is provided, but the additional element may become detached if the weld connection is defective and/or exposed to corrosion
Solution Approach 1:
The stop structure is merged with the base material through the groove feature, creating an integral connection that eliminates weld joints. This merging ensures that the stop cannot detach as there is no separate element to fail, and no weld connection to corrode.
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 solution provides a cost-effective, crack-free, and structurally robust eccentric stop that maintains component strength and stability, allowing for reliable adjustment of wheel tracking and camber without additional material or process weaknesses.
Implementation Method 1
a tab (8) formed from the base material and folded relative to a body portion (6) of the chassis suspension component and having a recess (10) surrounding the slot (4)
Data Source
AI summary
The invention relates to a chassis suspension component with a bracket made from a formable base material, preferably sheet steel, and comprising at least one slot for receiving a connecting bolt and at least one stop for an eccentric disc which is or can be connected rotationally fixedly to the connecting bolt. In order to be able to produce the eccentric stop process-reliably and economically without the risk of crack formation, the invention proposes to provide a tab formed from the base material and folded relative to a body portion of the suspension component and having a recess surrounding the slot, which recess defines two elongate stop faces running parallel to each other, wherein the stop faces serve as a stop for the eccentric disc. The invention also relates to a method for producing a chassis suspension component.