Vehicle Hinge Cold-Forming for Durable Two-Shear Connections
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Solution Overview
Problem
Existing methods for manufacturing heavy-duty vehicle hinges are costly due to high welding expenses or require high-pressure forming, and involve complex manual handling.
Innovation Solution
A method using a manufacturing apparatus that forms a two-shear connection through a cold-forming process with a hinge bolt and U-shaped hinge support, employing a press piston to deform the hinge limbs while using low-tensile material, ensuring a durable form-fit and press-fit connection with minimal manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug welding is used to connect the hinge bolt to the hinge body, then the connection durability is improved, but the manufacturing cost increases due to welding expenses and complex positioning requirements
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a cold-forming mechanical pressing system. The press tool deforms the hinge bolt end to create a form-fit connection with the limb, eliminating welding operations and associated costs while maintaining connection durability through precise mechanical interlocking.
Solution Approach 2:
The hinge bolt is designed with a specific geometry (cylindrical end portion) that enables it to form its own connection with the hinge body limb through cold forming. The bolt's own material properties and geometry are utilized to create the durable connection, reducing the need for additional welding materials or complex positioning fixtures.
2Strength
If cold forming with high press force is used to connect hardened or high-tensile hinge bolts, then the connection strength is improved for heavy duty use, but the manufacturing cost increases due to higher pressing cycles and press tool investment
Solution Approach 1:
The patent changes the material parameter of the hinge bolt from hardened or high-tensile material to low-tensile material. This parameter change allows the cold-forming process to be performed with lower press forces, reducing press tool investment and manufacturing costs while still achieving sufficient connection strength for the intended application.
Solution Approach 2:
The low-tensile material is specifically used for the hinge bolt portion that requires deformation (the end portion that forms the connection), while other parts of the hinge assembly can maintain their required strength properties. This localized material selection optimizes the balance between formability and overall connection strength.
3Ease of manufacture
If cold forming with low press force is used on low-tensile material, then the manufacturing cost is reduced, but the connection durability may be compromised for heavy duty applications
Solution Approach 1:
The patent employs a cylindrical (curved surface) press contour that deforms the hinge bolt end into a rounded, form-fit connection with the limb. This curved geometry distributes the contact stress more evenly and creates a mechanically interlocking shape that enhances connection durability despite the lower press forces used with low-tensile material.
Solution Approach 2:
The hinge assembly uses a composite approach combining low-tensile material for the deformable bolt portion with potentially different materials for the hinge body and limbs. This material combination allows the bolt to be easily formed while the overall assembly maintains the strength and durability required for heavy duty applications.
4Reliability
If welding is used to connect both limbs to the hinge bolt, then the connection reliability is improved, but the device complexity increases due to requiring two welding heads or turning pieces
Solution Approach 1:
The patent merges the two separate welding operations (one for each limb) into a single cold-forming operation. The press tool simultaneously or sequentially deforms the hinge bolt to create form-fit connections with both limbs, eliminating the need for multiple welding heads, positioning adjustments, and turning operations, thereby reducing device complexity while maintaining connection reliability.
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 process reduces manufacturing costs and complexity by using a simple apparatus with low press forces, achieving a robust and cost-effective hinge connection suitable for heavy-duty applications.
Implementation Method 1
A method for forming a hinge having a two-shear connection using a manufacturing apparatus... through a cold-forming process... employing a press piston to deform the hinge limbs
Data Source
Figure 1~2
Figure 3A~3D
Figure 4A~4D
AI summary
A hinge (19) is formed having a hinge bolt (30) and a U-shaped hinge support (20) with a hinge base (22), an upper limb (24) and a lower limb (25), with the upper limb having upper edges (29a, 29b, 29c) and a bolt bore (26). The hinge bolt has a main cylindrical portion (32) and at one end, a bolt head (31), a stepped tapering (33) adjacent the bolt head and a protrusion (34). The method includes placing the hinge support in manufacturing apparatus (100) having a support base (105), a workpiece holder (200) having a fixed clamping jaw (220) and a movable clamping jaw 230, a tool die (150) which includes a tubular die support (160) and a press contour (170), and a press piston (300), movable along a first axis to apply an adjustable pressing force on the hinge support.