Wedge-Locked Piston Rod Attachment for Lighter Vehicle Dampers
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Solution Overview
Problem
Existing vibration dampers for vehicles face challenges in achieving weight and material savings on piston rods while maintaining strength and continuous loading properties, leading to higher component weights, costs, and reduced damper performance.
Innovation Solution
The use of a vibration damper design that includes a piston rod with wedge element cut-outs and a bracing element, allowing for a secure and stress-free attachment of an attachment element via wedge elements, which reduces component weight, improves stress distribution, and lowers manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded connection is used to attach attachment element to piston rod, then secure attachment is achieved, but component weight and material consumption increase
Solution Approach 1:
The attachment system is divided into separate components: a piston rod with integrated wedge element cut-outs, detachable wedge elements, and an attachment element. This segmentation allows for optimized material usage in each component while maintaining secure attachment through the wedge mechanism that distributes loads effectively.
Solution Approach 2:
The invention changes the attachment mechanism from threaded connection to wedge-based connection. This parameter change in the attachment method enables weight reduction because wedge elements can be optimized for specific load conditions and require less material than threaded connections while maintaining secure attachment.
2Reliability
If threaded connection is used to attach attachment element to piston rod, then attachment security is achieved, but manufacturing costs increase
Solution Approach 1:
By segmenting the attachment system into modular components (piston rod, wedge elements, attachment element), the manufacturing process is simplified. Each component can be manufactured separately using optimized processes and then assembled, reducing overall manufacturing complexity and cost.
Solution Approach 2:
Changing from threaded connection to wedge connection alters the manufacturing requirements. Wedge elements with cut-outs can be manufactured more efficiently than threaded features, reducing machining costs and material consumption while maintaining attachment security.
3Strength
If larger piston rod diameter is used to maintain strength, then strength is improved, but friction increases due to larger contact area
Solution Approach 1:
The wedge elements are designed to distribute loads locally at specific contact points rather than requiring a larger overall piston rod diameter. This local quality optimization provides the necessary strength where loads are applied while minimizing the overall contact area and resulting friction.
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
This design achieves lower component weights with identical or improved strength, reduced friction due to a smaller contact area, and more secure attachment methods with reduced errors, while being more cost-effective and inclined to bend rather than break under overload.
Implementation Method 1
at least one wedge element (10, 10'), which in the braced state are arranged in the at least one wedge element cut-out (11, 11')
Data Source
AI summary
A vibration damper may comprise a damper tube filled at least partially with damping liquid. A piston rod is movable to and fro in the damper tube, and a working piston is movable with the piston rod. The working piston may divide an interior space of the damper tube into a piston rod-side working space and a working space distal the piston rod. A piston rod attachment may include an attachment element, a bracing element, and a wedge element. On a side that faces away from the working piston, the piston rod may have a wedge element cut-out for partially receiving the wedge element in a braced state. The attachment element may be connected to the bracing element such that the attachment element braces the bracing element with respect to the piston rod via the wedge element arranged in the wedge element cut-out.