Two-Piece Reserve Tube Shell for Hydraulic Damper Manufacturing
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Solution Overview
Problem
Conventional hydraulic dampers or shock absorbers face challenges in efficiently managing fluid volume changes during piston movement, leading to suboptimal damping characteristics and increased manufacturing complexity due to the need for seamless tubes and multiple welding operations.
Innovation Solution
A hydraulic damper design featuring a reserve tube formed from two open shells joined at longitudinal seams, allowing for customizable thickness and features, which surrounds a pressure tube to control fluid flow and damping characteristics, and a method for manufacturing this design using tailor-made metal sheets and welding to reduce complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seamless tube is used to form the reserve tube, then manufacturing precision and structural integrity are improved, but manufacturing complexity and cost increase due to the need for specialized seamless tube production and multiple welding operations
Solution Approach 1:
The reserve tube is divided into two separate open shells that are formed independently and then joined together. This segmentation allows each shell to be manufactured using standard sheet metal forming processes, avoiding the complexity of producing a seamless tube while maintaining structural integrity through the joined construction.
Solution Approach 2:
The invention changes the manufacturing parameters from requiring seamless tube production to using sheet metal forming and welding. This parameter change enables the use of more common, cost-effective manufacturing processes while achieving the same functional result.
2Strength
If multiple welding operations are performed to attach sheet metal components to the seamless tube, then structural strength is improved, but manufacturing time and cost increase
Solution Approach 1:
The two open shells are merged into a single integrated structure that forms the complete reserve tube. This merging reduces the number of separate welding operations needed, as the shells are joined to each other rather than requiring separate attachments to a pre-formed tube, thereby improving manufacturing efficiency while maintaining structural strength.
3Ease of manufacture
If a two-piece shell design is used for the reserve tube, then manufacturing flexibility and cost are improved, but manufacturing precision may deteriorate due to the need to join two separate components
Solution Approach 1:
The joining area between the two open shells is designed with specific local features such as overlapping edges and weld preparations that ensure precise alignment and connection. This local quality enhancement at the joint area compensates for the potential precision loss from using two separate components, while the rest of the shells can be manufactured with standard tolerances.
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 enhances damping control by managing fluid volume changes effectively and simplifies manufacturing through reduced welding and increased precision, lowering production costs and complexity.
Implementation Method 1
A base valve assembly, positioned at one end of the pressure tube, controls fluid flow between the lower working chamber and the reserve chamber to accommodate for changes in the fluid volume displaced by the length of the piston rod positioned inside the upper working chamber
Implementation Method 2
A piston assembly coupled to a piston rod is slidably disposed in the pressure tube and divides the working chamber into an upper working chamber and a lower working chamber
Implementation Method 3
They are used to absorb and dissipate the impact and rebound movement of the vehicle's suspension system
Implementation Method 4
A first valving system, typically incorporated within the piston, functions to create a damping load during the shock absorber's extension stroke
Data Source
AI summary
A shock absorber pressure tube defining a working chamber is provided. A piston assembly coupled to a piston rod is slidably disposed in the pressure tube and divides the working chamber into upper and lower working chambers. A reserve tube surrounds the pressure tube to define a reserve chamber. A base valve assembly, position at one end of the pressure tube, controls fluid flow between the lower working chamber and the reserve chamber. The reserve tube comprises first and second open shells that are joined together at longitudinal seams to create a substantially cylindrical shape. The first and second open shells may be made from patchwork blanks, tailor welded blanks, tailor rolled blanks, or tailor heat treated blanks to give different portions of the first and second open shells different thicknesses, strengths, properties, or characteristics.