Electrical Auxiliary Module for Vehicle Steering Systems
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Solution Overview
Problem
Conventional auxiliary devices for vehicle steering systems are inefficient, requiring lengthy design and manufacturing processes, have low mechanical efficiency, and are cumbersome to repair due to complex structures and large volumes, making them unsuitable for versatile use in different vehicle types.
Innovation Solution
An electrical auxiliary module comprising a gearbox with a sun gear, planet gear assembly, driven gear, and torque detector, connected to a motor and controller, which allows for modular design, improved mechanical efficiency, and easy detachment for maintenance, enabling compact and versatile application across various vehicle designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional pinion type auxiliary device with worm gear is used, then power transmission is achieved, but mechanical efficiency is low (about 85%) and power consumption is high
Solution Approach 1:
The patent replaces the conventional worm gear mechanical transmission system with an electric motor-driven system. The motor directly drives the pinion gear through a simplified gear assembly, eliminating the need for worm gear mechanisms. This substitution of mechanical transmission with an electromechanical system achieves higher efficiency (reducing power loss) while maintaining the required torque multiplication function through the motor's electromagnetic force and simplified gear reduction.
2Adaptability or versatility
If conventional auxiliary devices are designed based on different vehicle types, then specific vehicle requirements are met, but design term is long and manufacturing is sophisticated
Solution Approach 1:
The patent designs a universal auxiliary device with a standardized motor-driven gear assembly that can be adapted to different vehicle types and steering systems. The modular design allows the same basic structure to serve multiple vehicle applications, eliminating the need for lengthy redesign processes for each vehicle type while maintaining compatibility with various steering configurations.
Solution Approach 2:
The auxiliary device is divided into modular components: a standardized motor unit, a gear assembly, and mounting structures. This segmentation allows for easy adaptation to different vehicle types by simply changing mounting configurations or gear ratios while keeping the core mechanism unchanged, significantly reducing design time and manufacturing complexity.
3Ease of repair
If conventional auxiliary devices are disassembled for repair, then damaged components can be replaced, but the whole steering system has to be detached and wheels need realignment
Solution Approach 1:
The patent designs the auxiliary device as a self-contained, extractable module that can be removed from the steering system without detaching the entire steering assembly. The motor-driven unit is mounted as a separate auxiliary component that interfaces with the existing steering mechanism, allowing it to be easily extracted and replaced independently, thus avoiding wheel realignment procedures.
4Power
If planetary gear transmission is placed far from output drive gear, then power transmission is achieved, but volume of power steering system is too large for small vehicles
Solution Approach 1:
The patent employs a compact planetary gear mechanism where the planet gears are nested around the sun gear, and the entire planetary assembly is integrated within a compact housing that is positioned close to the output drive gear. This nested arrangement achieves efficient power transmission with minimal space, allowing the power steering system to fit within the limited space of small vehicles while maintaining adequate power transmission capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The electrical auxiliary module enhances mechanical efficiency, reduces power and oil consumption, simplifies design and manufacturing, and facilitates easy maintenance by allowing individual components to be replaced without disassembling the entire steering system, making it suitable for diverse vehicle applications.
Implementation Method 1
The motor is mounted on the casing of the gearbox with fasteners and is connected co-axially to the sun gear
Implementation Method 2
The planet gear assembly is mounted in the casing, engages the sun gear and has a driving gear, multiple planet gears and an annular gear. The planet gears are mounted rotatably on the driving gear and engage the sun gear
Implementation Method 3
The planet gear assembly... engages the sun gear... The annular gear is mounted around and engages the planet gears
Implementation Method 4
The torque detector is mounted on the casing of the gearbox with fasteners and is mounted around the driving axle to detect torque applied on the driving axle
Implementation Method 5
The controller is connected electrically to the motor and the torque detector to adjust torque output from the motor according to the torque detected by the torque detector
Data Source
AI summary
An auxiliary module has a gearbox, a motor, a torque detector and a controller. The gearbox has a casing, a sun gear, a planet gear assembly, a driven gear and a driving axle. The planet gear assembly engages the sun gear and has a driving gear, multiple planet gears and an annular gear. The planet gears are mounted rotatably on the driving gear and engage the sun gear. The annular gear is mounted around and engages the planet gears. The driven gear engages the driving gear. The driving axle is mounted co-axially on the driving gear. The motor is connected co-axially to the sun gear. The torque detector is mounted on the casing of the gearbox with fasteners to detect torque applied on the driving axle. The controller is connected electrically to the motor and the torque detector to adjust torque output from the motor.