Method and device for manufacturing a monotube shock absorber

1. A method of assembling a damper comprising:

inserting a floating piston into a cartridge;

engaging the floating piston with a stabilizer within the cartridge;

filling a region of the cartridge with oil;

inserting a piston-rod assembly into the cartridge, wherein engagement of the stabilizer with the floating piston inhibits the floating piston from exiting the cartridge while inserting the piston-rod assembly into the cartridge;

inserting a rod guide into the cartridge;

coupling a damper tube to the cartridge;

supplying a gas into the damper tube via a first end of the damper tube;

transferring the floating piston, the piston-rod assembly, the rod guide, and the oil from the cartridge to the damper tube through the first end of the damper tube; and

securing the rod guide to the damper tube.

2. The method according to claim 1 , wherein the floating piston, the piston-rod assembly, and the rod guide are inserted through a first end of the cartridge and the first end of the damper tube is coupled to a second end of the cartridge.

3. The method according to claim 1 , wherein the stabilizer is inserted into an end of the cartridge and inhibits the floating piston from exiting the end of the cartridge while inserting the piston-rod assembly from an opposite end of the cartridge.

4. The method according to claim 1 further comprising monitoring a pressure of the gas before transferring the floating piston, the piston-rod assembly, the rod guide, and the oil from the cartridge to the damper tube.

5. The method according to claim 1 , wherein securing the rod guide to the damper tube includes deforming the damper tube to engage the rod guide.

6. The method according to claim 1 further comprising:

separating the cartridge from the damper tube while holding the rod guide in the damper tube;

positioning a crimp tool around the first end of the damper tube; and

crimping the damper tube.

7. The method according to claim 6 , wherein the crimp tool engages the rod guide to inhibit axial movement of the rod guide relative to the damper tube while the crimp tool deforms the damper tube.

8. The method according to claim 1 further comprising coating an exterior surface of the damper tube with a protective coating prior to coupling the damper tube to the cartridge.

9. The method according to claim 8 , wherein the step of coating the exterior surface of the damper tube includes e-coating the exterior surface of the damper tube.

10. The method according to claim 1 further comprising:

operating a device that includes a plurality of stations; and

moving the cartridge with the floating piston, the piston-rod assembly, the rod guide, and the oil from one station of the plurality of stations to a subsequent station of the plurality of stations, wherein the damper tube is coupled to the cartridge at the subsequent station.

11. The method according to claim 1 , wherein the step of filling the region of the cartridge with oil fills a first region of the cartridge, wherein the method further includes filling a second region of the cartridge with oil after inserting the piston-rod assembly into the cartridge, wherein a piston of the piston-rod assembly separates the first region of the cartridge from the second region of the cartridge.

12. The method according to claim 1 further comprising operating a vacuum device to vacuum an inner surface of the cartridge.

13. The method according to claim 12 , wherein the vacuum device is connected to the stabilizer and the stabilizer includes an aperture through which the vacuum device vacuums the inner surface of the cartridge.

14. A method of assembling a damper comprising:

inserting a floating piston into a cartridge;

filling a region of the cartridge with oil;

inserting a piston-rod assembly into the cartridge;

inserting a rod guide into the cartridge;

coupling a damper tube to the cartridge;

supplying a gas into the damper tube via a first end of the damper tube;

transferring the floating piston, the piston-rod assembly, the rod guide, and the oil from the cartridge to the damper tube through the first end of the damper tube; and

securing the rod guide to the damper tube, wherein the method further comprises:

operating a device that includes a plurality of stations; and

moving the cartridge with the floating piston, the piston-rod assembly, the rod guide, and the oil from one station of the plurality of stations to a subsequent station of the plurality of stations, wherein the damper tube is coupled to the cartridge at the subsequent station.

15. The method according to claim 14 , wherein the plurality of stations are disposed about a central axis and moving the cartridge from the one station to the subsequent station includes rotating the cartridge about the central axis.

16. The method according to claim 15 , wherein the floating piston is inserted into the cartridge at a first station of the plurality of stations, the method further comprising:

moving the cartridge to a second station of the plurality of stations wherein the region of the cartridge is filled with the oil;

moving the cartridge to a third station of the plurality of stations wherein the piston-rod assembly is inserted into the cartridge;

moving the cartridge to a fourth station of the plurality of stations wherein the damper tube is coupled to the cartridge;

moving the cartridge to a fifth station of the plurality of stations wherein the gas is supplied into the damper tube;

moving the cartridge to a sixth station of the plurality of stations wherein the floating piston, the piston-rod assembly, the rod guide, and the oil are transferred from the cartridge to the damper tube; and

moving the cartridge to a seventh station of the plurality of stations wherein the rod guide is secured to the damper tube.

17. The method according to claim 16 further comprising moving the cartridge to an eighth station of the plurality of stations wherein a reaction force of the gas is measured.

18. A method of assembling a damper comprising:

inserting a floating piston into a cartridge supported by a frame at a first station;

moving the cartridge to a second station and filling a region of the cartridge with oil at the second station;

moving the cartridge to a third station and inserting a piston-rod assembly and rod guide into the cartridge at the third station;

moving the cartridge to a fourth station and sealing a first end portion of a damper tube to the cartridge at the fourth station;

moving the cartridge to a fifth station and supplying a gas into the damper tube through an aperture in the first end portion of the damper tube at the fifth station;

moving the cartridge to a sixth station and transferring the floating piston, the piston-rod assembly, the oil, and the rod guide from the cartridge to the damper tube through the aperture in the first end portion of the damper tube at the sixth station;

separating the cartridge from the damper tube; and

moving the damper tube to a seventh station and securing the rod guide in the first end portion of the damper tube.

19. The method according to claim 18 , wherein moving the cartridge between stations includes rotating the frame about an axis.

20. A method of assembling a damper comprising:

inserting a floating piston into a cartridge;

filling a region of the cartridge with oil;

inserting a piston-rod assembly into the cartridge;

inserting a rod guide into the cartridge;

coupling a damper tube to the cartridge;

supplying a gas into the damper tube via a first end of the damper tube;

transferring the floating piston, the piston-rod assembly, the rod guide, and the oil from the cartridge to the damper tube through the first end of the damper tube; and

securing the rod guide to the damper tube,

wherein the method further comprises coating an exterior surface of the damper tube with a protective coating prior to coupling the damper tube to the cartridge,

wherein the step of coating the exterior surface of the damper tube includes e-coating the exterior surface of the damper tube.