Torque Rod Axial Bearing Attachment Without Metal Screws
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pendulum supports for vehicle applications are heavy due to metal screws used for attaching axial bearing elements, which increases production costs and energy consumption, and are not suitable for lightweight electrical vehicles.
Innovation Solution
A pendulum support with a cross-sectionally reduced section made of full material, featuring a non-rotationally symmetrical rectangular cross-section, where the elastic bearing element is directly attached to the support arm without screws, using a friction stir welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal screw is used to secure the axial bearing element to the support arm, then the connection strength and reliability are improved, but the weight of the pendulum support increases
Solution Approach 1:
The invention extracts and removes the metal screw from the assembly, replacing it with a friction stir welding process that directly joins the aluminum support arm to the bearing element housing, thereby eliminating the heavy fastener while maintaining connection strength
Solution Approach 2:
The mechanical screw connection system is replaced with a friction stir welding process that creates a metallurgical bond between components, substituting a heavy mechanical fastening system with a lighter permanent joint
2Ease of manufacture
If a hollow cylindrical section is created in the support arm for screw insertion, then the bearing element can be secured, but the manufacturing complexity and production costs increase
Solution Approach 1:
The invention removes the hollow cylindrical section and threaded hole from the support arm design, eliminating the need for post-casting machining operations while maintaining the ability to securely attach the bearing element through friction stir welding
Solution Approach 2:
The invention changes the manufacturing approach from mechanical fastening requiring hollow sections and threads to friction stir welding that works with solid extruded sections, fundamentally altering how the components are joined
3Reliability
If a heavy metal screw is used to fasten the bearing element, then the connection reliability is improved, but the energy consumption increases
Solution Approach 1:
The heavy mechanical screw connection is replaced with a lighter friction stir welded joint that achieves equivalent or superior connection reliability while reducing the mass that contributes to energy consumption during vehicle operation
4Reliability
If threaded holes are formed in the support arm for screw engagement, then the bearing element can be securely attached, but the production costs increase
Solution Approach 1:
The invention extracts and eliminates the threaded hole formation step from the manufacturing process, using friction stir welding to create strong attachments without requiring any post-extrusion machining or threading operations
Solution Approach 2:
The friction stir welding process performs the attachment function during the primary manufacturing process rather than as a subsequent operation, integrating the joining step into the base material formation
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 reduces the weight and production costs of the pendulum support, allows for a more efficient use of materials, and is suitable for lightweight electrical vehicles by eliminating the need for metal screws and hollow cylindrical sections.
Implementation Method 1
using a friction stir welding process
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a pendulum support which has at least one axial bearing element (2, 21), specifically a resilient bearing element (2, 21) extending in the direction of the longitudinal extent of the supporting arm (1) of the pendulum support. At an axial end (17) of the supporting arm (1), the at least one bearing element (2, 21) is pushed onto a portion (5) which has a reduced cross-sectional area (13) and adjoins a shoulder (4). Unlike in previously known pendulum supports, this portion (5) of reduced cross-section has a cross-sectional area (13) which is not rotationally symmetrical and deviates from a circular shape. A stop washer (6), which is disposed axially at the end of the portion (5) of reduced cross-section, for the or an axial bearing element (2, 21) is fastened, while dispensing with a metal screw which passes axially through this portion (5) and is usually used for this purpose, directly to the portion (5) of reduced cross-section or is fixed thereto in the axial direction (a) via means (20, 20'; 21, 21') which are directly fastened to the portion (5).