Thrust Lever Ball Head Assembly with Integral Flange
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Solution Overview
Problem
Traditional thrust lever ball head assembly methods are complex, costly, heavy, and difficult to maintain, with issues such as axle displacement and low assembly efficiency due to interference fits and self-lock structures.
Innovation Solution
A thrust lever ball head assembly with integral flange structures that snap fit onto a radially or axially pre-compression styled elastic ball hinge, using a double-acting oil press assembly method to ensure a simple, lightweight, and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If interference fit is used for metal coat or elastic bodies, then the connection strength is improved, but the structure complexity and manufacturing difficulty increase
Solution Approach 1:
The ball head is divided into two separate parts: the main body and the flange structure. This segmentation allows the flange to be pressed independently onto the ball hinge, simplifying the assembly process while maintaining connection strength through the dedicated pressing mechanism.
Solution Approach 2:
A pressing device is introduced as an intermediary tool to facilitate the assembly process. The pressing device applies controlled force to press the flange onto the ball hinge, ensuring proper interference fit without requiring complex manual operations or specialized equipment.
2Reliability
If traditional assembling methods with self-lock structures are used, then the connection reliability is improved, but the assembling efficiency decreases
Solution Approach 1:
The flange structure is designed with pre-compression styling, meaning the compression force is built into the structure itself. This preliminary action ensures that the flange maintains constant pressure on the ball hinge after assembly, providing reliable connection without requiring complex self-lock mechanisms or additional fastening steps.
3Strength
If thick metal coat is used to ensure enough interference fit, then the connection strength is improved, but the weight increases
Solution Approach 1:
By separating the ball head into main body and flange components, the interference fit is concentrated in the flange area where it is most needed for connection strength. This allows thinner overall wall thickness while maintaining adequate interference fit at the critical joint, thereby reducing weight.
4Manufacturing precision
If internal circlip or shaft clamp ring is used to limit ball hinge, then the positioning accuracy is improved, but the structure complexity and assembly difficulty increase
Solution Approach 1:
The limiting function is merged into the flange structure itself rather than being a separate component. The flange's geometry and pressing action inherently constrain the ball hinge position, eliminating the need for additional circlips or clamp rings while maintaining positioning accuracy.
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 simple structure, high assembly efficiency, low manufacturing costs, and reduced maintenance, ensuring the thrust lever ball head assembly meets lightweight requirements while preventing axle displacement.
Implementation Method 1
an apparatus for assembling the thrust lever ball head assembly, comprising a double-acting oil press
Implementation Method 2
radially pre-compression styled elastic ball hinge of an integral rubber body, or a radially pre-compression styled elastic ball hinge of an integral metal coat, or an axially pre-compression styled elastic ball hinge of the metal lids on both sides
Data Source
AI summary
The current invention discloses a thrust lever ball head assembly comprising a thrust lever ball hinge and a thrust lever ball head. The thrust lever ball head comprises a main body of the thrust lever ball head and flange structures on both sides of the main body of the thrust lever ball head, wherein the flange structures and the main body of the thrust lever ball head are an integral part, and the flange structures on both sides of the main body of the thrust lever ball head work together with the thrust lever ball hinge to limit the thrust lever ball hinge inside the thrust lever ball head. The thrust lever ball head assembly of the present invention has a simple structure, high assembling efficiency, low manufacture costs, light weight, free of maintenance and completely fulfills the requirements of light weight.