Vibration Damper Plastic Deformation Assembly

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Solution Overview

Problem

Existing twin tube vibration dampers have increased complexity and production costs due to the need for precise press-fitting of inner components, making them difficult to produce on existing monotube damper manufacturing plants and requiring higher assembly precision.

Innovation Solution

A vibration damper design that uses plastic deformation of the outer and inner tubes to create a positively locking connection with a guide unit and bottom unit, eliminating the need for press-fitting and allowing for simpler, cost-effective assembly and production on existing plants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If press-fitting is used to connect inner components in twin tube dampers, then a secure connection is achieved, but manufacturing complexity and production costs increase

Engineering Contradiction:

Improveconnection securityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the connection method from press-fitting to plastic deformation. The outer tube is plastically deformed to form a bead that locks the guide unit in place, eliminating the need for precise press-fitting while maintaining connection security. This parameter change in the connection mechanism resolves the contradiction between reliable connection and manufacturing simplicity.

Inventive Principle:

Principle #35Parameter changes

2Strength

If press-fitting is used for inner components, then connection strength is improved, but assembly precision requirements increase

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The guide unit is pre-positioned within the inner tube before the outer tube is deformed. The plastic deformation of the outer tube then permanently secures the guide unit in its predetermined position. This preliminary positioning eliminates the need for high-precision assembly during final assembly, as the plastic deformation process itself ensures proper positioning and secure connection.

Inventive Principle:

Principle #10Preliminary action

3Strength

If press-fitting is used to connect components, then structural integrity is maintained, but production costs increase

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The outer tube serves a dual function: it provides structural support and simultaneously creates the locking connection through plastic deformation. The bead formed by deforming the outer tube performs both the sealing and locking functions, eliminating the need for separate fastening components and reducing production costs while maintaining structural integrity.

Inventive Principle:

Principle #25Self-service

4Reliability

If press-fitting is used for inner components, then connection reliability is improved, but ease of manufacture decreases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidease of manufacture

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical press-fitting system with a plastic deformation system. Instead of using hydraulic presses to force components together with precise interference fits, the outer tube is plastically deformed to create a permanent mechanical lock. This substitution maintains connection reliability while dramatically simplifying the manufacturing process and equipment requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces production costs, simplifies assembly, and provides a robust, secure connection that is less dependent on precise dimensional accuracy, enabling the vibration damper to be manufactured on existing monotube damper production lines while maintaining functional reliability.

Implementation Method 1

The outer tube and the inner tube are deformed plastically, with the result that the guide unit is connected in a positively locking manner to the outer tube and the inner tube

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS11655874B2Vibration damper, and motor vehicle with a vibration damper of this type

Publication Date: 2023.05.23 THYSSENKRUPP BILSTEIN GMBH

AI summary

A vibration damper for a motor vehicle includes an outer tube and an inner tube arranged coaxially within the outer tube. A guide unit closes the outer tube and the inner tube in each case at a first end. A bottom unit has a bottom valve. The bottom unit is arranged at a second end of the inner tube. The outer tube and the inner tube are deformed plastically, such that the guide unit is connected in a positively locking manner to the outer tube and the inner tube, and the inner tube being deformed plastically, such that the bottom unit is connected in a positively locking manner to the inner tube, and/or the outer tube and the inner tube is connected in an integrally joined manner to the guide unit, and the inner tube being connected in an integrally joined manner to the bottom unit.