Two-Piece Suspension Bar Pin Assembly for Weight and Cost Reduction
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Solution Overview
Problem
Current vehicle suspension bushing assemblies, particularly in heavy trucks, are heavy and costly due to the use of one-piece bar pins, which are difficult to manufacture efficiently, leading to excess material waste and increased costs.
Innovation Solution
A two-piece bar pin assembly is introduced, where the first and second bar pin components are formed separately and pressed together to form a closed cavity, allowing for weight savings and reduced manufacturing costs through cold forming or machining processes, maintaining or improving NVH performance, strength, and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece bar pin is used in the bushing assembly, then the structural integrity and simplicity are maintained, but the weight and manufacturing cost increase
Solution Approach 1:
The bar pin is divided into two separate components (first bar pin component and second bar pin component) that are assembled together to form the complete bar pin assembly. This segmentation allows each component to be optimized independently, enabling weight reduction through material removal or hollow construction while maintaining the overall structural integrity of the assembled bar pin.
2Device complexity
If a one-piece bar pin is used in the bushing assembly, then the assembly is simple, but the manufacturing complexity and material waste increase
Solution Approach 1:
Dividing the bar pin into two manufacturable components allows each piece to be produced more efficiently using standard manufacturing processes, reducing material waste from machining operations. The segmented components are then assembled into the final bar pin assembly, maintaining assembly simplicity while improving manufacturing efficiency.
Solution Approach 2:
The two-piece design allows for more efficient use of material during manufacturing, reducing scrap and waste compared to machining a one-piece bar pin. Excess material can be minimized in each component during the forming process, and the components are joined to create the final assembly, effectively recovering material efficiency.
3Weight of moving object
If a two-piece bar pin assembly is used, then weight and manufacturing costs are reduced, but the assembly complexity increases
Solution Approach 1:
The bar pin is segmented into two components that can be independently optimized for weight reduction. Each component can be designed with hollow sections or reduced material thickness while maintaining strength. The segmentation enables weight reduction without significantly increasing assembly complexity, as the components are designed to fit together straightforwardly.
4Ease of manufacture
If traditional one-piece bar pins are manufactured, then manufacturing processes are straightforward, but material waste and costs increase
Solution Approach 1:
The two-piece bar pin design enables more efficient material utilization during manufacturing. Each component can be formed or machined to minimize excess material, and the assembly process joins these optimized components. This approach recovers material efficiency compared to traditional one-piece manufacturing, reducing overall material waste and associated costs.
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 two-piece bar pin assembly achieves weight savings and reduced manufacturing costs while maintaining or improving noise, vibration, and harshness (NVH) performance, strength, and durability, addressing the inefficiencies of traditional one-piece bar pins.
Implementation Method 1
The two-piece bar pin assembly is arranged/assembled such that the first and second inboard ends of the first and second bar pin components are received in the inner sleeve in a press fit with the first and second inboard ends of the first and second bar pin components abutting one another.
Data Source
AI summary
A bushing assembly, such as for a vehicle suspension, includes inner and outer sleeves, a bushing disposed radially between the inner and outer sleeves, and a two-piece bar pin. The two-piece bar pin is configured such that a first inboard end of a first bar pin component is received in one end of the inner sleeve and a second inboard end of a second bar pin component is received in the other end of the inner sleeve. One or both of the first and second inboard ends of the first and second bar pin components has a closed end bore such that the first and second bar pin components cooperate to form a closed cavity within the two-piece bar pin assembly for weight saving purposes when the first and second inboard ends of the first and second bar pin components are pressed into the inner sleeve.