Torque Rod Two-Piece Mating Design Reducing Welds
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Solution Overview
Problem
Existing torque rods face issues with wear and fatigue due to varying operating conditions and road vibrations, leading to premature failure, and require custom manufacturing for different vehicle applications, which is costly and labor-intensive.
Innovation Solution
A two-piece mating design for torque rods, comprising forged steel outer portions with alignment grooves and holes for precise assembly, and sealed inner portions with radial ball designs and thermoplastic materials for enhanced durability and reduced friction, allowing for standardized manufacturing and customization during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple welds are used to construct torque rods from separate pieces, then manufacturing flexibility is improved, but structural strength and reliability deteriorate due to weld points being potential failure points
Solution Approach 1:
The patent combines multiple separate torque rod pieces into a single forged unit, eliminating weld points while maintaining the ability to create different lengths and configurations. This single-piece construction removes the weak points associated with welding while preserving manufacturing flexibility through post-forging cutting and machining operations.
2Adaptability or versatility
If torque rods are custom-manufactured for different vehicle applications, then adaptability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent creates a universal torque rod design where a single basic forged unit can be adapted to multiple vehicle applications through selective cutting, machining, and configuration modifications. This standardized base design maintains adaptability across different vehicles while significantly reducing manufacturing complexity compared to completely custom designs for each application.
3Strength
If torque rods are made from solid rod designs, then structural strength is improved, but weight increases compared to tubular designs
Solution Approach 1:
The patent applies local quality by using solid forged material only where structural strength is critical (at stress concentration points and connection areas) while using tubular or reduced-section material in less critical areas. This localized material distribution optimizes the strength-to-weight ratio by placing material strategically where it provides maximum structural benefit.
4Ease of manufacture
If standardized torque rod designs are used across different vehicles, then manufacturing cost decreases, but adaptability to specific vehicle needs deteriorates
Solution Approach 1:
The patent implements dynamics by creating a modular torque rod system where a standardized base design can be dynamically adapted to specific vehicle requirements through selective modification of length, diameter, and configuration. This allows the same core design to serve multiple applications while maintaining cost efficiency through standardized manufacturing processes for the base component.
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 design increases rigidity, reduces welds, and provides improved durability and reduced friction, enabling torque rods to handle higher payloads while being adaptable to various vehicle lengths with easier installation, thus extending the life of the components and reducing manufacturing costs.
Implementation Method 1
sealed inner portions with radial ball designs
Data Source
AI summary
The present invention is directed to a torque rod comprised of a two piece mating design which increases rigidity and reduces the number of welds. Unlike other designs this design has single piece forged ends which permits the torque rod of the present invention to take greater payloads than other designs can take. The design further includes internal bearings.