MXPA99009606A - Device and method for closing a movable socket and establishing a predetermined wear indicator distance - Google Patents

Abstract

An assembly technique and device for enclosing an open end of a movable socket (10) comprised of fully hardened materials with an expanding cover-plate (66) and for positioning the cover-plate at a predetermined distance from an exposed pressure plate (62) of the movable socket so as to provide a reliable indicator of socket wear. During assembly, various internal components of the movable socket, including the pressure plate, are installed within a housing (12) through a posterior opening (16) with the cover-plate is positioned over the components. A two-stage ram (100) having first and second contact surfaces (142, 167) is brought into engagement with the cover-plate. Pressure exerted by the two-stage ram is transferred to the cover-plate through the first surface, expanding the cover-plate into a generally planar configuration and enclosing the internal components within the socket housing. A continued increase in pressure extends the second contact surface into engagement with the cover-plate, further deforming the cover-plate to a predetermined final position relative to an internal component for a consistent indication of wear on the socket components within the housing.

Description

DEVICE AND METHOD FOR CLOSING A MOBILE RECEPTACLE AND ESTABLISH A DEFAULT DISTANCE OF INDICATION OF WEAR BACKGROUND OF THE INVENTION This invention relates to the manufacture and assembly of mobile receptacles, for example, ball joints such as those used in automotive steering and suspension systems, and very particularly, to a method and device for performing double operations of closing one end of a mobile receptacle without shaping, upsetting or welding, by means of an expandable cover plate, and for establishing a desired wear indicating distance between the surface of the expandable cover plate and a pressure plate enclosed within the receptacle. Although the invention is described in detail with respect to automotive applications, those skilled in the art will recognize the broader applicability of the invention. Conventional ball joints and other movable receptacles are used, for example, in steering and automobile suspension applications. The receptacles comprise a housing having a circular cylindrical internal surface, a ball bolt with a ball head contained in the housing, and a synthetic resin or concreted alloy bearing member that supports the ball head within the housing. These components are installed in the housing through a rear opening, the ball bolt extending outwardly through an axially disposed front opening of a diameter smaller than that of the ball head. Traditionally the rear opening is closed by means of a cover plate shaped, stressed or welded in place. Once secured in place, the cover plate presses the bearing member either directly or indirectly through an intermediate elastic rubber component and a pressure plate. The bearing components within the housing, against which the ball head or movable component is articulated, act best when the housing material is fully hardened, as it is more able to withstand the stresses and frictional wear associated with movement. of the bearing components. Consequently, the use of hardened materials extends the useful life of the bearing components and the housing extensively. However, surfaces of hardened material largely prevent the traditional shaping, upsetting and welding operations required to enclose the housing. Therefore, as described in the co-pending patent application of E.U.

Serial No. /, (incorporated herein by reference), a method and device is used to expand a conical or convex cover plate into the rear opening to secure and enclose the components of the receptacle within the receptacle housing. , allowing the closure of a completely hardened housing without the need for traditional shaping, upsetting or welding operations. Once assembled, the movable receptacles can be used as load bearing members in numerous mechanical systems, including suspension and steering systems for automotive vehicles. Obviously, the mobile receptacles or swivels used in these applications are subjected to various operating conditions, and may require substantial loads. When wear develops, the performance of the mobile receptacle or ball joint is degraded and, in the case of automotive applications, this can cause erratic steering or excessive looseness and play in the vehicle suspension system. As written in the patent E.U. No. 4,070,121 to Graham, it is known to manufacture movable receptacles and ball joints with exposed wear indicators that extend through the cover plate so that they are in position to provide a visual indication of the wear condition of the components. of the kneecap. As the components of the ball joint wear out over time due to friction, the position of the exposed wear indicator moves, corresponding to changes in the distance between the cover plate and the internal components of the ball joint. Traditionally, the distance between the outer surface of the cover plate and the internal pressure plate of the ball joint is used to determine the amount of wear experienced by the receptacle. To ensure an accurate wear indication, this distance is established, with a minimum of part-to-part variation, to a predetermined tolerance by a secondary press or machining operation after the closing of the mobile receptacle or ball joint by means of traditional forming operations, upsetting or welding. Accordingly, it is highly advantageous to develop a ram device capable of both expanding a conical or convex cover plate within a receptacle housing to enclose the housing without the need for specialized forming, upsetting or welding operations, and establishing the distance between them. the expanded cover plate and the receptacle pressure plate at a predetermined reference for wear indication in a single machining operation.

BRIEF DESCRIPTION OF THE INVENTION Among the various objects and advantages of the present invention are: The provision of an apparatus for expanding a conical or convex cover plate for securing ball-and-socket components within a ball-and-socket housing and for setting the cover plate at a predetermined position to provide an indication of the wear of the ball joint component in a continuous two-stage operation; The provision of the aforementioned apparatus, in which a first contact surface expands the cover plate within the housing, and a second contact surface independently sets the cover plate expanded at the predetermined wear indicating position. The provision of the aforementioned apparatus, wherein the first and second contact surfaces are concentrically mounted within a ram housing; The provision of a method for using the aforementioned apparatus, wherein the operation of expanding the cover plate and the operation of positioning the cover plate are integrated in a continuous two-stage pressing operation: The provision of the method of aforementioned use, wherein the operation of expanding the cover plate is a first stage operation, and the operation of positioning the cover plate is a second stage or sequential operation; and The provision of the aforementioned apparatus and method, which simplify the assembly and manufacture of mobile ball joints at close tolerances, while providing minimal variations from unit to unit. Briefly mentioned, the present invention relates to an assembly technique for enclosing an open end of a mobile receptacle comprising fully hardened materials with an expandable cover plate and for placing the cover plate at a predetermined distance from the internal components of the receptacle mobile to provide a reliable indicator of receptacle wear. During assembly, several internal components of the mobile receptacle, including a pressure plate, are installed within a housing through a rear opening, and a conical or convex cover plate is placed over the components within the rear opening. A ram of the present invention having concentric contact surfaces is brought into engagement with the cover plate. The pressure exerted by the ram is transferred to the cover plate through an outer concentric surface, expanding the cover plate in a generally flat configuration and enclosing the internal components within the receptacle housing. Once the cover plate has expanded, a continuous increase in the pressure exerted by the ram extends an inner concentric contact surface in engagement with the cover plate, deforming the cover plate to a predetermined end position. The predetermined final position of the expanded cover plate provides a reference plane for a consistent indication of wear on the receptacle components within the housing. The foregoing and other objects, features and advantages of the invention, as well as the presently preferred embodiments thereof will become more apparent upon reading the following description in connection with the accompanying drawings: BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings that form part of the description: Figure 1 is an exploded view of an illustrative embodiment of a movable receptacle assembly employing the expandable cover plate of the present invention; Figure 1A is a partial view illustrating the moving receptacle of Figure 1A, with the top end components in place, before the expansion of the cover plate; Figure 2A is an exploded perspective view of a two-stage assembly tool of the present invention; Figure 2B is a sectional view of the two-stage assembly tool shown in Figure 2A; Figure 3A is a side sectional view of a cylindrical housing for a two-stage assembly tool of the present invention; Figure 3B is a front end view of the cylindrical housing shown in Figure 3A; Figure 4A is a front end view of a housing adapter for a two-stage assembly tool of the present invention; Figure 4B is a side sectional view of the accommodation adapter shown in Figure 4A; Figure 5A is a side sectional view of a mounting adapter for a two-stage assembly tool of the present invention; Figure 5B is a front end view of the mounting adapter shown in Figure 5A; Figure 6A is a side sectional view of a second stage deflection ram for a two stage assembly tool of the present invention; Figure 6B is an elongation of a portion of Figure 6A indicated on line 6B-6B, illustrating the beveled leading edge; Figure 6C is an anterior end view of the second stage deflection ram of Figure 6A; Figure 7 is a sectional view similar to that of Figure 2B, illustrating the work surface of a removable stop plate that is in engagement with a fully expanded cover stage and the rear opening shoulder of a ball housing; Figure 8A is a sectional view of a movable receptacle after the first stage expansion of the cover plate by the work surface of the removable stop plate, which illustrates the expanded cover plate at high tolerance. the placement of the pressure plate; Figure 8B is a sectional view similar to that of Figure 8A, illustrating at low tolerance end the expanded cover plate and the positioning of the pressure plate; Figure 9 is a view similar to that of Figures 8A and 8B, illustrating the relative positioning of the ball joint components and the two stage assembly tool after the completion of the first stage expansion process; Fig. 10 is a view similar to that of Fig. 9, illustrating the relative position of the ball joint components and the two-stage assembly tool after completing the second stage deformation process, prior to the removal of the ram from second stage deflection and Figure 11 is a side sectional view of a fully assembled mobile receptacle after expansion of the cover plate and establishment of the wear indicator distance by the tool and method of the present invention; The corresponding reference numbers indicate corresponding parts along the different figures of the drawings.

DESCRIPTION OF THE PREFERRED MODALITY The following detailed description illustrates the invention by way of example and not by way of limitation. The description clearly makes it possible for one skilled in the art to make and use the invention, describes various embodiments, adaptations, variations, alternatives and uses of the invention, including what is currently believed to be the best way to carry out the invention. Referring generally to FIGS. 1 and 1A, the two-stage expandable cover plate assembly method of the present invention can be used to enclose a movable pocket, such as the ball joint shown at 10, within a housing 12 without the need of forming, upsetting or welding. Those skilled in the art will readily recognize the applicability of the following method to assembling a variety of different moving receptacles. To facilitate the description of the method and devices used in conjunction therewith, the preferred embodiment of the present invention is described with reference to a ball joint 10, but is not limited to being used with it. The housing 12, inside which the different internal components of the patella are enclosed is generally cylindrical, with a central hole 14 of a non-uniform radius having a rear opening 16 and a front opening 18. The radius R of the central hole 14 decreases to define a curved surface 20 at the base of the housing, adjacent to the front opening 18. A recessed hole 22 having a circumferential groove 24 is formed in the hole 14, adjacent to the rear opening 16. The outer surface 26 of the housing 12 can follow the general contour of the central hole 14. In the illustrated mode, the surface 26 has an expanded edge 28 formed therein. The edge 28 is used for joining the ball joint 10 to other components (not shown). As can be appreciated, the edge 28 can also be adapted for other specific types of installations employing threads or other connectors (not shown). To assemble the ball joint 10, a bearing 30 configured to fit inside the central hole 14 is seated within the housing 12. The bearing 30 includes a central hole 32 axially aligned with a vertical axis VA of the housing, and a curved outer surface 34 of the bearing 30 is designed to correspond to the curvature of the surface 20 in the housing 12. Next, a bolt 36 having a generally cylindrical body 38 and an elongated head portion 40 with a circumferential flange 42 is passed through central holes 32 and 14, such that the lower side 44 of the flange 42 rests on an upper surface 46 of the bearing seated within the housing. The body 38 includes an upper portion of uniform diameter 50 adjacent the flange 42, a tapered central portion 52 and a lower portion 54 of a narrow uniform diameter. The upper portion 50 is configured to fit within the central hole 32 of the bearing 30, the central portion 52 and the lower portion 54 extending through the front opening 18, externally of the housing 12. The head portion 40 includes a hemispherical surface 56. with a radius RH larger than that of the upper portion 50, but lower than the radius R of the housing 12. When assembled, the hemispherical surface 56 and the curved outer surface 34 define a generally spherical unit within the housing 12, allowing movement Bolt 36. Those skilled in the art will readily recognize that numerous shapes and configurations are possible for the bolt 36 and the bearing 30. For example, the bolt 36 may include a generally spherical head, eliminating the need for the bearing 30, or the Cylindrical body can include threads (not shown), holes as in 58 or slots as in 60, for fixing the composites external events (not shown). Once the bolt 36 and the bearing 30 are seated within the housing, a pressure plate 62 and a rubber cushion 64 are placed inside the central hole 14, on the hemispherical surface 56, and are secured there by a cover plate. expandable 66 having an axial hole 67 as described below. The pressure plate 62 sits on top of the bolt 36, and includes a curved indentation 68 having a radius of curvature corresponding to RH. In the preferred embodiment a lubrication port 70 is formed and extends upwards along the center of the pressure plate 62. The port 70 allows the injection of a lubricant into the lower spaces of the assembled ball joint 10. The cushion of rubber 64 sits, in turn, on an upper surface 72 of the pressure plate 62, and serves to hold the pressure plate 62 in place against the bolt 36, while simultaneously allowing small movements in response to the conical movement of the cap screw. The rubber pad includes a circumferential torus 74 having an axial bore 76 formed therein through which the lubrication port 70 extends. Finally, the cover plate 66 shown in a non-expanded conical configuration in FIG. It is placed on the rubber cushion 64 adjacent the counterbore 22, for vertical compression and lateral expansion as will be described, to settle inside the circumferential groove 24 and to enclose the different components within the housing 12. To facilitate the insertion of the plate of cover 66 within the rear opening of the housing 12, the cover plate 66 includes a circumferential rib 78 having an outer diameter OD adapted to fit within the hole 22, and an axial hole 67 configured such that the lubrication port 70 of the pressure plate 64 can pass through it. Figure 1A illustrates the exposure of the components of the ball joint 10 before the expansion of the cover plate 66. As indicated above, those skilled in the art will recognize that the various internal components of the mobile receptacle secured within the housing 12 by the cover plate 66 may vary in size and shape depending on the particular application for which the mobile receptacle is designed, and accordingly, the kneecap 10 described above is simply exemplary of one modality. The method of assembly described in the co-pending patent of E.U. Serial no. /, To install the expandable cover plate 66 is applicable to any movable receptacle in which one end of the housing 12 must be enclosed to hold the internal components in place. Returning to Figure 2a to Figure 6c, a two-stage assembly tool or ram for use with the expandable cover plate 66 as described in the copending application mentioned above is generally shown at 100. The two-stage assembly tool 100 comprises a cylindrical housing 102 (Figures 3A and 3B) having a central axis CA, mounted concentric to a housing adapter 104 (Figures 4A and 4B). The housing adapter 104 includes an axially aligned passage 105 and is secured to a rotating head adapter 106 by a number of retaining bolts 108 circumferentially spaced around the CA axis. Each retaining bolt 108 is secured to a threaded cavity 109 in the accommodation adapter 104 through a threaded hole 110 in a circumferential rim 112 of the rotating head adapter 106. In the preferred embodiment shown in Figures 2A and 2B, the rotating head adapter 106 is configured with an external surface 114 for attachment to the driving member of a hydraulic or pneumatic press (not shown), and the accommodation adapter 104 is secured to the rotating head adapter 106 by three bolts of identical retention equidistantly spaced apart 108. A number of ports 11 for equalizing the air pressure within the two-stage assembly tool 100 and for introducing a lubricant thereto into the accommodation adapter 104 is also included. as required. The cylindrical housing 102 of the two-stage assembly tool 100 includes a hole 116 concentric with the central axis CA and a circumferential shoulder 10 coming out inwardly adjacent a rear end 120 of the hole 116. When assembled, as best seen in Figure 2B, the shoulder 118 sits against a circumferential shoulder 122 on the accommodation adapter 104, thereby maintaining the housing portion 102 on the pivot head adapter 106. The front end 124 of the housing 102 is enclosed by a mounting plate 126 (shown in Figures 5A and 5B) secured to the housing portion 102 by a number of recessed head screws 128 screwed into cavities 129. In the preferred embodiment, a total of six socket head screws 128 they are spaced apart equidistantly around the circumference of the front end 124. The mounting plate 126 comprises a bull body 127 which has a ne a rectangular cross-sectional shape and is configured with a number of flanges for the attachment of several components. First, an outer circumferential flange 130 extends radially outwardly of the body 127 to settle on the forward end 124 of the housing 102. The flange 130 includes a number of identical countersunk threaded holes 132 through which the identical head screws 128 pass. into the interior of the housing 102. Those skilled in the art will recognize that the number of holes 132 corresponds to the number of head screws 128 used to retain the mounting plate 126 to the housing 102. Extending radially inwardly from the body 127, a circumferential rim interior 134 defines an axial passage 136 through mounting plate 126. Finally, a cylindrical rim 138 on the front surface of the body 127 defines a recessed assembly 140 within which a removable stopping plate 142 is secured. As described in the co-pending patent application E.U. No / ____, the stop plate 142, best shown in Fig. 2A, includes a work surface 144 configured to deform a conical or convex cover plate 66 in an essentially planar configuration and an elongated axial hole 145. The plate Stop 142 is secured within the recessed assembly 140 by a number of identical head screws 146, each threaded through identical radial holes 148 in the cylindrical rim 138 and into a receiving channel 150. In the preferred embodiment, as noted in Figure 2A, a total of three head screws 146 are spaced equidistantly about the central axis CA to hold the stop plate 142 within the recessed assembly 140, however, one skilled in the art will recognize that numbers may be employed larger or smaller head screws within the scope of this invention, and that the receiving channel 150 may be replaced by a number of receiving cavities disposed substantially (not shown). Axially disposed within the hole 116 is a second stage baffle 158, shown in greater detail in Figure 6A - Figure 6C, having a cylindrical body 160 and a longitudinal hole 162 axially aligned with the central axis CA. The trailing end 164 of the body 160 configured to extend within the accommodating adapter axial passage 105 of the accommodating adapter 104 has an outer diameter D1 corresponding to the inner diameter D2 of the passage 105. A circumferential retaining groove 165 adjacent the trailing end 164 receives an O-shaped washer 167. An anterior end 166 of the body 160 has a reduced diameter D3 and is configured to extend through the axial passage of mounting plate 136 and partially into the elongated axial hole 145 of the stop plate 142. The leading end 166 includes a circumferential edge 167, bevelled outwardly at an acute angle, preferably 20 degrees as shown in Figure 6B. A spring support flange 168 surrounds the outer surface of the body 160 at the transition point between the body diameters D1 and D3. Equivalently spaced apart around an inner surface 170 of the support flange are a number of identical recessed spring seats 172, better seen in Figure 6C. Those skilled in the art will recognize that the number of recessed spring seats may vary within the scope of the present invention. To provide a compressive force acting on the second stage baffle 158, a number of compressible spring members 174A-174P are concentrically placed around the body 160, between the rear end 164 and a rear surface 176 of the spring support flange 168 When installed within the housing 102, the spring members 174A-174P are seated between the rear surface 176 and the accommodation adapter 104. In the preferred embodiment, the spring members 174A-174P are each individual bellville washers, classified for flat loads of 618 kilos each, placed in four groups of four. Each is aligned opposite adjacent groups as shown in Figures 2A and 2B, providing a larger overall compression distance, while limiting the individual compression distance at which each spring member moves. In the preferred embodiment, the resulting spring member stack 174A-174P has a load rating of 2,067 kilograms, with a compression distance of 0.36 cm. In order to keep the second stage deflector 158 in a retracted position in the elongated axial hole 145 of the stop plate 142, a number of expansion springs 180, each identical and preferably coil-wound springs, are placed parallel to the central axis CA. , between the anterior surface 170 and the inner circumferential rim 134 of the mounting plate 126. The expansion springs 180 are seated within the recessed spring seats 172 on the spring support flange 168 and identical axially aligned seats 182 on the mounting plate flange 134. It will be readily apparent to those skilled in the art that the number of seats 182 and 172 will correspond to the number of expansion springs 180 employed to support the second stage deflector 158. In the preferred embodiment illustrated, five expansion springs 180 are used and correspondingly, five pairs of seats are axially aligned and arranged equidistantly on the spring support flange 168 and the mounting plate flange 134. The operation of the compressible spring members 174A- 174P and of the expansion springs 180 will be described in better detail below. The final internal components of the two-stage assembly tool 100 comprise a number of large diameter compressible spring members 182A-182H, coaxially disposed about the central axis CA within the housing bore 116, adjacent to the inner surface of the cylindrical bore. 102, as best seen in Figures 2A and 2B. These large diameter compressible spring members are seated in a slightly compressed configuration between the rear surface of the housing adapter 104 and the front surface of the mounting plate bull body 127 to provide a preload of approximately 1.04 kg on the plate. assembly 126. In the preferred embodiment, the large diameter spring members 182A-182H are each individual bellville washers, each with a flat load rating of 2,715 kilograms and placed in four groups of two. Each group is aligned in opposition to adjacent groups as shown in Figure 2, providing a larger overall compression distance and limiting at the same time the compression distance in which each individual spring member moves. In the preferred embodiment, the stack of resultant large diameter compressible spring members 182A-182H is rated at 4,241 kilograms with 0.711 cm compression distance. One skilled in the art will recognize that alternative types of compressible spring members such as helically wound springs can be employed within the scope of the invention, as long as the load requirements are met. By compressing or slightly preloading the large diameter compressible spring members 182A-182H, the expansion force of approximately 1.044 kg is coaxially directed along the central axis CA, causing the accommodation adapter 104 and the mounting plate 126 stay in opposite directions. As is readily apparent from the examination of Figure 2, the mounting plate 126 is secured to the cylindrical housing 102, which is in turn seated against a surface of the accommodation adapter 104. The load on the rear surface 156 of the The mounting plate 126 is transferred to the housing 102 through the recessed head screws 128, causing the shoulder 118 of the housing 102 to sit securely against the circumferential rim 122 of the accommodation adapter 104. It is then observed that the force of expansion maintains the housing 102 and associated components against the accommodation adapter 104. Referring to Figures 2A and 2B, the assembly of the two stage stopping assembly tool 100 of the present invention begins with the cylindrical housing 102 and the accommodation adapter 104. The accommodation adapter 104 is placed within the housing 102, adjacent the rear end, such that the circumferential shoulder 122 on the accommodation adapter is seated against the shoulder 118 of the housing 102. Then, the large-diameter compressible spring members 182A-182H are stacked within the housing bore 116, resting a spring member 182A directly on the front surface of the accommodation adapter 104. Similarly, the spring members 174A-174p are stacked within the remaining portion of the housing bore 116, concentrically inwardly to the large diameter compressible spring members 182A- 182H, a spring member 174A resting within the recessed shoulder 178 on the accommodation adapter 104. With the spring members 174A-174p and 182A-182H stacked in place, the second stage baffle 158 and its associated O-shaped washer 167 are seated within the spring members 174A-174p, such that the rear end 164 of the body 160 extends into the axial passage of the accommodation adapter 105 , and the rear surface of the spring support flange rests against the spring member 174p. Expansion springs 180 are then seated within the recessed spring seats 172A-172E on the front surface of the spring support flange. To enclose the housing 102, the mounting plate 126 is axially aligned with the central axis CA and placed against the front end 124 of the housing 102, compressing the large diameter spring members 182A-182H and the expansion springs 180. Then the thread embedded head screws 128 into the housing 102 through the mounting plate holes 132, securing the mounting plate in a fixed relationship with the housing and retaining the second stage baffle 158 within the housing bore 116 in such a manner that a small degree of axial movement of the deflector is allowed. All axial movement of the second stage baffle 158 is restricted by the expansion springs 180 and the spring members 174A-174p. The two-stage assembly tool 100 is then secured to the rotating head adapter 106 by keeping the bolts 108 threaded through the hole 110 in the rim 112 of the rotating head adapter and into the housing adapter 104. The final step in the assembly of the tool 100 is the selection and fixation of the removable stop plate 142. As described in the co-pending patent application E.U. Serial No. /,, the removable stop plate includes work surface 144 configured to deform a conical or convex cover plate 66, and is accordingly selected to correspond to the size and shape of the cover plate. The removable stopping plate 142 is axially positioned within the recessed assembly 140 on the mounting plate, 126 and secured thereto by placing head screws 146 threaded through the flange 138 of the mounting plate 126 and into the channel of reception 150 of the stop plate 142. The two-stage assembly tool 100 as described above is used in the closing operations of a ball joint 10 as follows. First, the internal components of the ball joint 100 are stacked within the ball socket 12 as described in the copending U.S. patent application. Serial No. / _, and placed in axial alignment under the two-stage assembly tool 100, previously secured to a hydraulic or pneumatic press (not shown) by the rotary head adapter 106. The initial operation of the Two-stage assembly tool to close the kneecap is as described in the co-pending application. A downward force is exerted by the hydraulic or pneumatic press, moving the work surface 144 of the removable stop plate 142 in contact with the expandable cover plate 66. A continuous downward force exercise by the hydraulic press or pneumatic displaces the accommodation adapter 104 in an axially downward direction relative to the cylindrical housing 102 of the two-stage assembly tool 100, compressing the large-diameter spring members 182A-182H. The downward force exerted by the The press is now transferred through the spring members 182A-182H to the work surface 144, and continues the time necessary until the closing of the patella 10 is complete by expanding the plate. cover 66 as described in the co-pending application. In the mode? Preferred, the pneumatic hydraulic press must exert a load of at least 2,445 kilos on the cover plate 66 to achieve the desired expansion and closing of the patella 10. After the complete expansion of the cover plate 66 and the closing of the ball joint 10, the work surface 144 makes contact with the upper surface of the counterbore 22 in the ball joint housing 10, and its further downward movement is blocked as shown in figure 7. As shown in Figure 8A - Figure 9, closing the ball housing 10 by the expanded cover plate 66 results in a certain degree of dimensional variation from a high tolerance position (Figure 8A) in which the plate Expanded cover 66 may actually equal, or slightly above, the lubrication port 70 of the pressure plate 62, to a low tolerance position (Figure 8B) in which the expanded cover plate 66 is slightly below the portion highest of the pressure plate 62. The dimensions included in Figure 8A and Figure 8B are exemplary. Figure 9 illustrates the preferred dimensional relationships after completing the expansion process of the cover plate of the first stage. Accordingly, establishing a predetermined distance of indication of wear between the expanded cover plate 66 and the highest portion of the pressure plate 62, the hydraulic or pneumatic press continues to exert a downward load on the two-stage assembly tool 100, causing additional understanding of the large diameter spring members 182A-182H. Since further downward movement of the mounting plate 126 by the locked removable stop plate 142 is prevented, the load is transferred from the accommodation adapter to the second stage deflector 158 through the spring members 174A-174p. The second stage deflector 158 moves axially downward within the cylindrical housing 102, such that the beveled circumferential edge 167 on the forward end 166 of the deflector 158 makes contact with the expanded cover plate 66, adjacent to the exposed portion of the lubrication port 70. A continuous increase in the downward force exerted by the press results in the understanding of the spring member 174A-174p and a further downward deformation of the expanded cover plate 66 as the baffle 158 continues to move axially downward. The downward axial movement of the detector 158 and the deformation of the cover plate Expanded 66 stops when the front surface of the deflector 158 makes contact with the uppermost portion of the pressure plate 62, as shown in Figure 10. In the preferred embodiment, a downward load of at least 6,303 kilograms and no more of 7,497 kilos must be exercised by the hydraulic or pneumatic press to achieve the desired final deformation of the cover plate and xpap 66. After completion of the deformation of the expanded cover plate 66 by the second stage baffle 158, the load is removed from the second stage assembly tool 100, allowing the expansion springs 180 to axially retract the reflector 158 within of the cylindrical housing 102, and the removal of the two-stage assembly tool 100. By removing the reflector 158 from contact with the cover plate 66, the cover plate will spring back a small amount, and come to rest in a position predetermined in relation to the uppermost portion of the pressure plate 62 as shown in Figure 11. This distance, preferably 1.45 mm in the modes shown, is the wear indicator distance used by the service personnel to determine whether the Ball joint 10 has suffered excessive wear. Those skilled in the art will recognize that the spring member load requirements and the final deformation of the expanded cover plate 66, resulting in the predetermined wear indication distance can be adjusted as required to achieve alternative wear indicator distances, or as required to achieve adequate deformation of the composition of the manufacturing material of the cover plate 66 and the sizes of the components. In view of the foregoing, it will be noted that the different objects of the invention are achieved and that other advantageous results are obtained. Since various changes can be made to the above structures without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings be construed as illustrative and not in a limiting sense.

Claims (16)

NOVELTY OF THE INVENTION CLAIMS

1. - A cover plate assembly tool for reforming an expandable cover plate for enclosing an end of a movable receptacle housing having a protruding pressure plate, and for establishing a predetermined distance of indication of wear between said cover plate and a portion of said pressure plate, comprising: a two-stage ram adapted for use with a pressing machine, said two-stage ram has a work surface for expanding said cover plate under a first load, and a deflector of second step for deforming said cover plate under a second and greater load to a predetermined position, a distance corresponding between said deformed cover plate in said predetermined position and an upper surface of said pressure plate at said predetermined distance of indication of wear.

2. The cover plate assembly tool according to claim 1, further characterized in that said two-stage ram further includes: a cylindrical housing having a central axis; a first adapter seated concentrically to said central axis, adjacent a first end of said cylindrical housing, said first adapter has an axial hole of a first diameter and is configured to secure said two-stage ram to said pressing machine; a second adapter secured said housing concentric to the central axis and opposite said first adapter, said second adapter has an axial bore of a second diameter and configured to receive a removable stop plate configured to expand said cover plate; a plurality of compressible spring members arranged concentrically within said cylindrical housing, said compressible spring members are preloaded to exert an expansive force on said first and second adapters; and a second stage baffle axially disposed within said cylindrical housing, said second stage baffle has a rear end equipped with said first diameter axial bore of said first adapter, and a front end inserted into said second diameter axial bore. said second adapter, said forward end configured to deform said cover plate.

3. The cover plate assembly tool according to claim 2, further characterized in that said second stage deflector is restricted from axial movement by first and second sets of compressible spring elements, said first set of compressible spring elements. interposed between said first adapter and said second stage deflector, and said second set of compressible spring elements interposed between said second stage deflector and said second adapter.

4. - The cover plate assembly tool according to claim 3, further characterized in that said second stage deflector is configured to extend axially beyond said removable stop plate in response to an axial compression force on said first and second sets of compressible spring elements.

5. The cover plate assembly tool according to claim 2, further characterized in that said front end of said second stage deflector includes a bevelled rim concentric to said central axis, said bevelled rim configured to deform said cover plate .

6. The cover plate assembly tool according to claim 5, further characterized in that said front end of said second stage baffle includes a recessed surface for receiving an upper surface of said protruding pressure plate after the deformation of said plate. said cover plate at said predetermined distance of indication of wear.

7. The cover plate assembly tool according to claim 1, further characterized in that said working surface is concentric to said second stage deflector.

8. The cover plate assembly tool according to claim 2, further characterized in that said compressible spring members are bellville large diameter washers arranged in four adjacent sets.

9. The cover plate assembly tool according to claim 8, further characterized in that each of said four adjacent sets comprises two stacked bellville washers, each set arranged in mirror image relation to each adjacent set.

10. The cover plate assembly tool according to claim 3, further characterized in that said first set of compressible spring elements comprises a plurality of bellville washers arranged in a plurality of aligned groups.

11. The cover plate assembly tool according to claim 10, further characterized in that each of said aligned groups comprises four bellville washers, each group arranged in mirror image relation to each adjacent group.

12. The cover plate assembly tool according to claim 3, further characterized in that said second set of compressible spring elements comprises a plurality of spiral wound winding springs aligned in parallel to said central axis.

13. A method for enclosing an end of a movable receptacle within a housing having a protruding pressure plate with an expandable cover plate having a central hole, for establishing said expandable cover plate at a predetermined distance of indication from wear from a portion of said pressure plate, comprising the steps of: assembling internal components of said movable receptacle within said housing, with said expandable cover plate disposed on said internal components; placing a two-stage assembly tool in axial alignment with said expandable cover plate; exerting a load on said two-stage assembly tool such that the work surface of said two-stage assembly tool moves along said alignment axis to contact said expandable cover plate; increasing said load exerted to axially displace said work surface to contact said housing, displacing said work surface by expanding said expandable cover plate in a generally planar configuration and enclosing said internal components within said housing of said movable receptacle of said housing. such that an upper portion of said pressure plate extends over said expanded cover plate through said axial bore; deforming said expanded cover plate beyond a predetermined wear indication distance from said upper portion of said pressure plate further increasing said exerted load and extending a second stage deflector by axially mounting within said second stage assembly tool for contacting said upper portion of said pressure plate with said second stage baffle; and releasing said load exerted to remove said second stage baffle and said work surface from contact with said movable receptacle.

14. The method according to claim 13, further characterized in that increasing said load exerted on said second stage assembly tool compresses a plurality of compressible spring members disposed within said second stage assembly tool, transferring said exerted load to said work surface.

15. The method according to claim 13, further characterized in that by increasing more said exerted load a plurality of compressible spring elements disposed inside said second stage assembly tool is compressed, said increased exerted load being transferred to said deflector second stage, axially displacing said second stage deflector in relation to said work surface.

16. The method according to claim 13, further characterized in that deforming said expanded cover plate beyond a predetermined distance of indication of wear causes the recoiling of said deformed cover plate after releasing said exerted load, resulting in said deformed cover plate being placed in said predetermined distance of wear indication in relation to said upper portion of said pressure plate.