Cast Iron Steering Knuckle Structure for Low-Temperature Side Impact
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Solution Overview
Problem
Steering knuckles for commercial vehicles made of steel face limitations in shape and cost due to the forging process, and struggle to maintain load capacity and stability, especially at low temperatures, during side impacts.
Innovation Solution
A steering knuckle made of cast iron with a base body, cup-shaped receptacle, lining holder, and handlebar connection, featuring a ribbed indentation for stability and weight optimization, allowing for integrated assembly and reduced material duplication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel forging process is used for steering knuckle, then high strength and resilience are achieved, but shape variability is limited and manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from steel to cast iron, which fundamentally alters the manufacturing capabilities. Cast iron enables complex three-dimensional shapes with varying wall thicknesses that cannot be achieved through traditional steel forging, while maintaining sufficient strength for steering knuckle applications.
Solution Approach 2:
The patent employs cast iron as a composite material solution, utilizing its unique properties of combining adequate strength with excellent castability. This allows the steering knuckle to achieve complex geometries including integrated brake carrier bridges and varying wall thicknesses that would be impossible with forged steel.
2Strength
If steel forging process is used for steering knuckle, then high strength is achieved, but manufacturing cost increases due to heat input and complex processes
Solution Approach 1:
The patent changes the material parameter from steel to cast iron, which fundamentally alters the manufacturing capabilities. Cast iron enables complex three-dimensional shapes with varying wall thicknesses that cannot be achieved through traditional steel forging, while maintaining sufficient strength for steering knuckle applications.
Solution Approach 2:
The patent merges multiple components into a single integrated cast iron steering knuckle. The brake carrier bridge is formed as an integral part of the knuckle body, eliminating separate manufacturing and assembly steps, thereby reducing overall manufacturing cost and complexity.
3Adaptability or versatility
If cast material is used for steering knuckle, then shape variability and assembly integration are improved, but stability at low temperatures during side impact may be compromised
Solution Approach 1:
The patent employs cast iron as a composite material solution, utilizing its unique properties of combining adequate strength with excellent castability. This allows the steering knuckle to achieve complex geometries including integrated brake carrier bridges and varying wall thicknesses that would be impossible with forged steel.
Solution Approach 2:
The patent applies local quality by varying the wall thickness in different regions of the steering knuckle. Thicker sections are provided in areas subject to high loads such as the brake carrier bridge and impact zones, while thinner sections are used where loads are lower, optimizing both strength and weight distribution for low-temperature reliability.
Data Source
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AI summary
A steering knuckle (1) of a utility vehicle, consisting of a casting material, has a main body (2), a steering knuckle bearing (3), a hub-type, cup-shaped receiving portion (4), open towards a rim of a vehicle wheel and suitable for receiving an anti-friction bearing (23) and a bearing journal (22), and a pad-receiving portion (5) for receiving a brake pad (27), said receiving portion having a support (6) and two supporting elements (7) provided one behind the other in the rotational direction of the vehicle wheel, a guide link (8) for linking an axle guide being formed on the main body (2).