TWI540074B - Methods and apparatus for structural reinforcement of vehicle suspension members - Google Patents

Description

Method and apparatus for structural reinforcement of vehicle suspension components Cross reference

The present application claims priority to U.S. Provisional Application No. 61/360,331, filed on June 30, 2010, which is incorporated herein by reference.

The invention relates to a vehicle suspension. In particular, the present invention relates to a method and apparatus for assembling a vehicle suspension.

Vehicle suspension systems typically include separate and unique structural members because their shape and construction materials must be fabricated separately and then assembled. Here, the component must resist the tendency to twist and/or bend. This generally means that the component structure must be assembled so that the relative axial and/or rotational motion between the particular components can be minimized. In many applications, certain suspension components may also be coated with a low friction and/or corrosion resistant material to improve performance. There is a need for a method and system for assembling a suspension component with other suspension components in a rigid interference manner without compromising any assembled components.

The present invention generally relates to a method and apparatus for assembling a vehicle suspension. In one embodiment, the method includes the steps of adjusting the temperature of the first suspension assembly and then pressing the first suspension assembly and the second suspension assembly together for engagement at a temperature that is substantially maintained at the adjustment. In one embodiment, the vehicle suspension is a fork.

The present invention may be understood from the following detailed description, the detailed description of the invention, It should be noted, however, that the drawings are intended to be illustrative of exemplary embodiments of the invention and are not intended to limit the scope of the invention.

In one embodiment, the suspension element includes two parts that are press-fit together, in the assembly step, by inserting the outer diameter surface of the first part into the inner diameter surface of the other part. In one embodiment, the vehicle is a two-wheeled vehicle such as a bicycle or a locomotive. Figure 1 is a perspective view of the fork 5. The fork 5 includes a pair of upper and front suspension fork branches 9 connected by a steering crown 10. The lower end of the fork tube interacts with the receiving member 8 to provide shock absorbing characteristics by the action of a spring and a damper mounted in the fork 5. As shown in Figure 1, the crown 10 is located at the upper end of the fork, where the crown is attached to each of the forks 9 and is used to convert a single tube 14 from a joystick (not shown) into a double tube fork. 5.

In one embodiment of the assembly method, the upper end of each of the fork branches 9 opposite the receiving member 8 is pressed into the opening of the respective circumference of the crown 10 in a direction 12 along the crown 10 11. Each opening 11 forms a passage to the inner diameter on each side of the crown (corresponding to the illustrated opening 11 respectively). Each inner diameter is slightly smaller than the outer diameter of one end of the corresponding branch 9 (for each branch 9 respectively), thereby allowing the branches to engage the crown opening 11 via a crimp fit.

During use of the suspension product comprising the branches 9/crown 10 assembly, the crimping creates an interference fit sufficient to hold or secure the fork branch 9 within the crown 10 in a generally rotationally and axially rigid manner. .

In one embodiment, the size of the inner diameter of the crown opening 11 is adjusted during thermal expansion by thermal expansion during assembly to avoid crowning the crown 10 (eg, the inner diameter of the opening 11) or branch 9 (eg, Substantial/structural damage of the outer diameter of the branch. Similarly, the outer diameter of the fork branches can be reduced to reduce size by, for example, applying a cooling method, such as by dipping the ends of the fork branches into a cryogenic liquid, such as nitrogen or more slowly, to dry ice. In other configurations, the inner and outer diameters can be adjusted to achieve and temporarily maintain variations in inner and outer diameter dimensions. In one non-limiting embodiment, a heating device such as an oven, such as a countertop convection oven, is preheated to 300 degrees Fahrenheit using any number of temperature monitoring devices, such as thermometers or infrared sensors. The crown 10 (or other heated part) is then placed into the oven and allowed to immerse in heat at a predetermined temperature and time period, such as 10 minutes. The fork branches 9 used to assemble the heated crown 10 are allowed to remain at room temperature of about 70 degrees Fahrenheit. The different temperature treatment of the crowns 10 and the fork branches 9 causes the inner diameter of the crown (of the opening 11) to expand relative to the outer diameter of the ends 13 of the branches 9. The coefficient of thermal expansion and the mass and size (and material, such as aluminum) of the crown 10 are such that when the crown is maintained at an elevated temperature such as 300 degrees Fahrenheit, the inner diameter of the crown 10 becomes greater than the The outer diameter of the end 13 of these branches 9. Aluminum has a positive thermal coefficient of 0.000023 mm per degree Celsius. For example, if a 1 meter stick is heated to 100 degrees Celsius, the length will expand by 2.3 millimeters. Similarly, the inner diameter of the tubular, such as the opening 11 of the aluminum crown, is thus increased in size such that the crown is more susceptible to receiving the engaged male fork tube while the crown remains immersed in heat (at elevated temperatures).

In a state where the crown 10 and the branch 9 are different in the aforementioned heat, the branches 9 can be assembled by inserting the branches 9 into the crown opening 11. However, this assembly must be performed relatively quickly and accurately to avoid heat transfer between the relatively cold branch 9 and the relatively hot crown 10, tending to balance the temperature between the two, thereby causing the branch 9 and the crown 10 to return The state in which the outer diameter of the branch 9 and the inner diameter of the opening 11 interfere with each other (thereby preventing the branch 9 from being completely axially inserted into the crown opening 11).

In order to facilitate accurate and reproducible accurate assembly, a press-fit device and assembly procedure are disclosed. Figure 2 illustrates a perspective view of an embodiment of a press 50 for assembling a suspension element. The press shows that the crown 10 is fixed to the upper end of the press at the lower end of the press and a pair of fork branches 9, and can be press-fitted into the opening 11 of the crown at any time. The press includes a carriage 18 that is axially movable up and down on the track 20, the track 20 being responsive to the leverage of the lever 17 (e.g., manually) and driving the carriage 18 generally in the direction 30 by the latch 31. The track 20 is secured to a base that includes a crown portion alignment pin 22 and a crown steering mount datum pin 23. The fork branch holders 21 (each for each tube) are secured to the carriage 18. In one embodiment, each fork branch 9 is adapted to pass through the inner diameter of one of the retainers 21 and remains fixed in tension with the carriage 18 at room temperature prior to assembly. Since the retainers shown engage the fork branches in a male/female relationship, the retainers can be easily fabricated to insert the inner diameters (IDs) of the fork tubes.

2A illustrates a partial enlarged view of the configuration of FIG. 2 and shows the relationship between the latch 22 and the opening 11 of the crown 10. Just prior to assembly, the crown 10 immersed in temperature is removed from the heat source (not shown) and placed in the "upside down" manner with the steering tube opening 24 at the steering mounting reference pin 23 (Fig. 2). . As shown in FIG. 2A, each opening 11 is adapted to the smaller aperture portion 22A of each alignment pin 22 and is centrally aligned with the smaller aperture portion 22B of the respective alignment pin 22. The conical shape 22C of the upper end of each of the pins 22 is used to provide alignment of the fork branches 9 when the fork branches 9 begin to contact the pins 22 during assembly. In the illustrated embodiment, the opening 11 of the crown 10 includes a shoulder 24 that is configured to fill the gap between the smaller aperture portion 22A and the inner diameter of the opening 11 as it moves into the opening during expansion. At the time of the groove 25, the end 13 of the branch 9 abuts.

Figure 3 illustrates the press 50 of Figure 2, additionally showing the assembled suspension of the fork branch 9 inserted into the crown 10. As shown, the pins 22, 23 are used to secure the crown 10 for positioning and to ensure that the opening 11 is properly aligned with the fork branches 9. The lever 17 is manually displaced to move the carriage 18 axially downward to engage the end 13 of each suspended, room temperature branch 9 with a respective heat immersed opening 11. The upper end of the alignment pin 22, the smaller aperture portion 22A is engaged by the inner diameter of the end 13 of the branch 9, as the branch 9 advances downwardly with the carriage 18. In one embodiment, the operator can continue to pull the lever 17 manually and smoothly until each branch 9 abuts the shoulder 24 of the opening 11 (Fig. 3A). The alignment pins 22 are configured such that each branch 9 is suitably assembled within the crown 10 by virtue of the branch 9 abutting the shoulder 24. In another embodiment, the branch 9 is attached when the branch 9 abuts against the large aperture thickened upset formed between 22A and 22B of the pin 22.

Fig. 3A shows a partial enlarged view of the configuration of Fig. 3 and shows the relationship between the assembled parts. As illustrated, the lower end 13 of the fork branch 9 has been lowered to pass between the inner diameter of the opening 11 and the outer diameter of the branch 9 through the conical 22C. The lowermost end of the branch is shown against the shoulder 24. The remaining portion of the groove 25 that is still present in the crimp fitting area is barely visible. The small opening represents the still expanding opening 11 which will continue to be immersed in heat throughout the assembly process.

After the branches 9 abut against the shoulder of the opening 11, the lever 17 is pulled up, and when the carriage 18 is lifted by the lever 17, the branches 9 fixed to the crown 10 at this time will be from the holder 21 keeps slipping out. Thereafter, the branch 9/crown 10 is removed from the press 50 and, optionally, placed in a separate cooling rack (not shown). The purpose of the rack is to maintain the newly assembled parts as well as to facilitate the cooling step so that the parts are presented at a uniform room temperature. In one embodiment, air or other suitable coolant is supplied through a line connecting the air knife, and the coolant gas system is blown from the air knife and causes the coolant gas to impinge on the area of the opening 11 and the end 13 just assembled. . The branch 9/crown 10 assembly remains under coolant flow until the assembly has cooled sufficiently (eg, the average temperature is below 100 degrees Fahrenheit).

After cooling, the branch 9/crown 10 assembly was placed through a test press to selectively test the assembly strength. In a typical test press, the branch 9/crown 10 assembly is supported on the platform by the crown 10 and the branches 9 are freely suspended. A press adapter is provided on each of the upper ends of the branches 9 (one on each branch) such that the press adapters axially abut the upper ends of the branches 9. The hydraulic fluid is then supplied to the pressure cylinder. Upon engagement, the test press is pressurized until axially downward produces a predetermined test force at the upper ends of the branches 9. In one embodiment, this force can be 300 pounds of force. By the standard of the test, the branches are not axially moved (relative to the fixed crown) under the application of the test force.

Figure 4 shows a flow chart generally relating to the steps of the assembly procedure described in this case. First, the temperature of the part is typically adjusted by the use of a temperature regulating chamber and the temperature is checked before reaching a predetermined temperature. The part is then installed in the press and the assembly operation begins when the part is assembled to a predetermined relative position within a predetermined time. The assembled part is then cooled in one of a number of different ways, and finally the connection completed by the program is tested.

The foregoing has exemplified the use of an embodiment comprising thermal expansion of the crown 10 under treatment of the corresponding branch 9, while other alternatives are equally applicable. For example, when the crown 10 is substantially maintained in ambient conditions, the branches 9 can be subjected to a low temperature treatment to reduce their aperture. In another alternative, the branches 9 can be treated at a low temperature when the crown 10 is treated at an elevated temperature. The assembly press 50 can be automated with a suitable air cylinder and delivered at a predetermined pressure "blowing" or overpressure release, as well as manual actuation. The oven can be used to heat the components and is equipped with a thermostat, an infrared thermal sensor to determine the part immersion time, and an automatic shutdown. In an alternate embodiment, the temperature adjustment device is incorporated into the press whereby the crown is thermally expanded and/or the branches are reduced in volume under cooling and in a "ready" position in the press. An alternative includes an inductive device that heats the aluminum crown by electromagnetic induction. At predetermined times, when their size has been temporarily changed by temperature processing, the parts are assembled and allowed to return to room temperature or to be cooled. Such arrangements are within the scope of this specification.

In one embodiment, the plurality of branch lines 9 overlay coatings, such as zinc or treated with Kashima ^TM or nitride, or other surface of the anode polarization, and is based in particular pressed to the formula or scoring assembly vulnerable Bruises. What is important is the integrity of the assembly so that the coating does not scribe or be scratched apart during assembly. The method and apparatus described in this application are well suited for such parts of the part to be pre-coated.

In one embodiment, the vehicle suspension fork includes a crown having first and second fork openings, the crown having a first fork retained within the first fork opening, wherein the retention creates a compressed ring Stress in the first fork tube, and the tensile ring stress is within the first opening, but does not create a substantial axial stress at the first tube or the first opening. The second fork tube remains in the second fork tube opening, wherein the retention creates a compressive ring stress in the second fork tube, and the tensile ring stress is within the second opening, but not in the second A substantially axial stress is generated at the tube or the second opening. The fork is made by adjusting a first portion of the suspension fork to a non-room temperature; accurately setting the first portion relative to at least a second portion of the suspension fork at substantially the non-room temperature that is maintained; And, the assembled portions are substantially returned to room temperature.

In another embodiment, the vehicle suspension fork includes: a crown having first and second fork openings; the first fork is retained within the first fork opening, wherein the retaining is within the first fork Producing a compressive ring stress and creating a tensile ring stress in the first opening, but not creating a substantially axial stress in the first tube or the first opening; the second fork is retained in the second fork In the tube opening, wherein the retaining system generates a compressive ring stress in the second fork tube and a tensile ring stress in the second opening, but does not generate a rough in the second tube or the second opening Axial stress. In one embodiment, the fork further includes a surface treatment disposed between the fork tubes and corresponding openings, wherein the surface treatment is substantially intact and compressed.

The foregoing is directed to the embodiments of the present invention, and other and further embodiments of the present invention can be devised without departing from the basic scope of the invention, and the scope of the invention is defined by the appended claims.

5. . . cross

8. . . Receiving member

9. . . Fork branch

10. . . Crown

11. . . Opening

12. . . direction

13. . . End

14. . . tube

17. . . lever

18. . . Carriage

20. . . track

twenty one. . . Maintainer

22, 23. . . plug

22A. . . Smaller aperture

22B. . . Smaller aperture

22C. . . Conical

twenty four. . . Shoulder

25. . . Trench

30. . . direction

31. . . plug

50. . . press

Figure 1 is a perspective view of a vehicle suspension, also referred to as a front fork.

Figure 2 is a perspective view of a press for assembling a suspension member, showing a fork crown at the lower end and a pair of fork branches fixed at the upper end.

2A is a partial enlarged view of a lower portion of the press of FIG. 2.

Figure 3 is a schematic illustration of the press of Figure 2 showing the assembled suspension after the fork branch has been inserted into the crown.

Figure 3A is a partial enlarged view of the lower portion of the press of Figure 3.

4 is a flow chart illustrating typical steps associated with the assembly of suspension elements in accordance with an embodiment of the present case.

Claims (18)

A method of assembling a suspension, the suspension having a first suspension assembly and a first and a second of a second suspension assembly, the first suspension assembly including at least one first and a second opening, wherein After assembly, the first person is fixed in the first opening, and the second person is fixed in the second opening, the method comprising the steps of: the first suspension assembly and the second suspension assemblies Forming a temperature difference therebetween; the first one of the second suspension assemblies adjacent to the first opening and aligned for placement is secured within the first opening; the second opening is immediately adjacent and aligned The second one of the second suspension assemblies for placement is secured within the second opening; the first and the first suspension assembly are operatively moved relative to the first suspension assembly Both to present the current temperature difference between the first suspension assembly and the second suspension assemblies such that the first one of the second suspension assembly engages within the first opening and the second The second person of the suspension assembly is engaged with the second Within the opening; and after bonding into the openings, release the plurality of first and second suspension component from fixing state. The method of claim 1, wherein the components are joined in a retractable relationship such that the first and second suspension assemblies reach a same temperature The components include a crimp fit between a concave portion of the first component and a convex portion of the second component. The method of claim 2, wherein the first component is a crown and the second component is a fork. The method of claim 3, wherein the temperature difference between the crown and the fork tubes is formed by heating the crown. The method of claim 4, wherein the crown is tied in a clamp, the clamp fixing the crown to a position relative to the fork tubes, whereby the convex shape of the fork tube when fixed A portion of the centerline is aligned with a centerline of the opening in the concave portion of the crown. The method of claim 1, wherein the first one of the second suspension assemblies that are immediately adjacent to the first opening and aligned for placement is secured within the first opening, and the second opening is immediately adjacent And the step of aligning the second one of the second suspension assemblies for placement in the second opening comprises the step of placing the first and second suspension assemblies into different holders. The method of claim 6, further comprising: moving the current temperature difference between the first suspension component and the second suspension components, and moving the A step of maintaining the first and second portions of the second suspension assembly in a direction of the first suspension assemblies. The method of claim 7, further comprising: presenting the current temperature difference between the first suspension component and the second suspension components, and when moving the a step of engaging the one end of the first and second with a protrusion radially projecting into the first and second openings of the first component, wherein the holder is the first of the second suspension assembly One and the second remain fixed in the direction of the first suspension assemblies. The method of claim 8, wherein the ends of the first and second portions of the second suspension assembly engage the projections in the first and second openings of the first assembly A portion of the first one of the second suspension assembly extends into the first opening and is spaced apart from a sidewall of the first opening by a groove. The method of claim 8, further comprising: a temperature difference between the first suspension component and the second suspension components is lower than when the first and second ones of the second suspension component are The step of removing the second suspension assemblies from the retainers after the temperature difference during movement within the openings of a suspension assembly. The method of claim 1, wherein an outer surface of the second suspension assemblies is coated with a corrosion resistant material. The method of claim 3, wherein the openings in the crown have a first inner diameter, and the fork tubes have an outer diameter, and when the fork tubes are at the same temperature as the crown, The outer diameter of the fork tubes is greater than the first inner diameter of the openings in the crown. A method of assembling a suspension, the suspension having a first suspension assembly and a first and a second of a second suspension assembly, the first suspension assembly including at least one first and one having an inner wall a second opening, the first one of the second suspension assembly and the second one having an outer wall, wherein after assembly, the first one is fixed in the first opening, and the second one is fixed to the In the second opening, the method includes the steps of: forming a temperature difference between the first and second suspension assemblies such that a portion of the second suspension assemblies are engageable within the openings of the first suspension assembly And the outer wall of the second suspension assembly does not contact the inner wall of the first or second opening; the second suspension assemblies are aligned with respect to the openings in the first suspension assembly; When the second suspension assemblies are aligned with respect to the openings of the first suspension assembly, the second suspension assemblies are simultaneously moved relative to the first suspension assembly such that the ends of the second suspension assemblies Entering the first suspension assembly Of the openings, and has a groove between the outer wall of the plurality of second suspension assembly with the inner walls of the openings. The method of claim 13, further comprising: aligning the second suspension assemblies with the openings of the first suspension assembly when the second suspension assemblies are moving relative to the first suspension assembly A step of. The method of claim 14, wherein the step of aligning the second suspension assemblies with the openings of the first suspension assembly comprises the step of aligning an inner diameter of the second suspension assemblies. The method of claim 14, wherein the second suspension assemblies remain fixed in the holder prior to the step of aligning the second suspension assemblies to the openings of the first suspension assembly. The method of claim 13 wherein an outer surface of the second suspension assemblies comprises a coating that is subject to abrasion. The method of claim 16 wherein the plurality of retainers are simultaneously moved to simultaneously move the second suspension assemblies relative to the first suspension assembly.