Chassis Actuator Flange Connection Torque Transfer
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Solution Overview
Problem
Existing roll stabilizers for vehicles face challenges in providing a functionally reliable and space-efficient mechanism for torque transfer and stabilization, particularly in actively counteracting rolling movements during curved driving, with existing designs often requiring non-weldable materials and complex assembly processes.
Innovation Solution
A chassis actuator device featuring a housing arrangement with a motor and transmission, utilizing a flange connection with positive-locking contours on lateral surfaces for secure torque transfer between the actuator and stabilization components, allowing for efficient torque transmission and compact design, with optional magnetic materials for sensor integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flange connection with positive-locking contours on lateral surfaces is used for torque transfer, then the device complexity is reduced and assembly is simplified, but the manufacturing precision requirements increase
Solution Approach 1:
The connection interface is segmented into discrete positive-locking contours (teeth) on both the flange and holder section. These segmented features engage with each other to provide positive mechanical locking, eliminating the need for complex welding procedures while maintaining connection reliability. The segmentation allows for simplified assembly through direct engagement of the contoured surfaces.
Solution Approach 2:
The positive-locking contours act as an intermediary mechanical feature between the flange and holder section. These contours provide a standardized interface that mediates the torque transfer, replacing complex welding operations with a simpler geometric engagement system that requires precise manufacturing but simplifies overall assembly procedures.
2Adaptability or versatility
If magnetic materials are used in the flange for sensor integration, then the adaptability of the device is improved, but the weight of the component increases
Solution Approach 1:
Magnetic material properties are applied locally to specific regions of the flange where sensor integration is required, rather than using magnetic material throughout the entire component. This localized application provides the necessary adaptability for sensor functionality while minimizing the overall weight increase of the flange assembly.
Solution Approach 2:
The flange utilizes composite construction combining magnetic and non-magnetic materials. Magnetic material layers or inserts are integrated into the flange structure only where sensor interaction is needed, allowing the majority of the flange to be made from lighter non-magnetic materials. This composite approach enables sensor integration capability while controlling the overall weight of the component.
Data Source
AI summary
Roll stabilizers as an example for chassis actuators are used for compensating or suppressing rolling movements of a vehicle about its longitudinal axis. Such rolling movements are caused, in particular, when driving around curves due to centrifugal forces. A chassis actuator device is provided, in particular, a roll stabilizer, for a vehicle with a flange connection between an actuator and a stabilization component. A holder-side positive-locking contour is arranged on a holder section of the flange connection and a flange-side positive-locking contour is arranged on a flange. The positive-locking contours together form a positive-locking connection in the circumferential direction about a torsion axis A, and the flange-side positive-locking contour is arranged on a flange-side lateral surface and/or the holder-side positive-locking contour is arranged on a holder-side lateral surface.