Vehicle Hinge Cold-Forming for Low-Cost Two-Shear Joints
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Solution Overview
Problem
Existing methods for manufacturing heavy-duty hinges for vehicles, such as agricultural equipment, are costly due to high welding costs or require high-pressure cold forming, which increases investment and manual handling.
Innovation Solution
A manufacturing apparatus and method using a U-shaped hinge support with a hinge bolt featuring a stepped tapering and protrusion, deformed using a press piston to create a form-fit and press-fit connection with low-tensile steel, reducing the need for high-pressure cold forming and minimizing manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect the hinge bolt to the hinge body, then the connection strength is improved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a cold forming mechanical process. The hinge bolt is cold-formed to create a deformation that mechanically interlocks with the hinge body, eliminating the need for welding while maintaining connection strength and reducing manufacturing costs.
Solution Approach 2:
The patent changes the material parameters of the hinge bolt by cold-forming it during assembly. The bolt undergoes plastic deformation to create a permanent shape change that forms the connection, transforming the bolt from a simple fastener into a structurally integrated component without requiring additional welding operations.
2Reliability
If high-pressure cold forming is used to deform the hinge bolt, then the connection durability is improved, but the investment cost and manual handling increase
Solution Approach 1:
The hinge bolt is pre-formed with specific geometric features (such as a deformation zone or asymmetric profile) before assembly. This preliminary shaping allows the bolt to be cold-formed into the hinge body with reduced force requirements, eliminating the need for high-pressure equipment while ensuring durable connection.
Solution Approach 2:
The hinge bolt is designed with segmented or zoned geometry, where different portions of the bolt have different properties. The deformation zone is specifically designed to undergo plastic forming at lower pressures, while other portions maintain their original strength, allowing durable connection without high-pressure equipment.
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 method achieves a cost-effective, durable two-shear connection with reduced manual handling and lower investment costs by using a press piston to deform the hinge support, ensuring a strong and efficient hinge assembly.
Implementation Method 1
The lower limb 25 is deformed by a press contour 170 of a tool die 150 so that material of the lower limb 25 comes into press-fit connection with the hinge bolt 30
Data Source
AI summary
A hinge is formed having a hinge bolt and a U-shaped hinge support with a hinge base, an upper limb and a lower limb. The method includes placing the hinge support in manufacturing apparatus having a support base, a workpiece holder having a fixed clamping jaw and a movable clamping jaw, a tool die which includes a tubular die support and a press contour, and a press piston. The press piston is movable along a first axis to apply an adjustable pressing force on the hinge support. The support base includes cylindrical guide shafts to movably guide the workpiece holder along a second axis. The hinge support is placed relative the workpiece holder such that upper edges of the upper limb are brought into contact with a first recess in the fixed clamping jaw and a second recess in the movable clamping jaw.