Motor Vehicle Front Structure With Annular Rack Seal Interface
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Solution Overview
Problem
The existing front structure of motor vehicles faces challenges in assembling the steering column and rack due to dimensional constraints, particularly the width of the border around the oblong orifice in the steering bowl, which becomes insufficient when the front side members are brought closer together to accommodate new wheel width and turning radius requirements.
Innovation Solution
A flat annular part is installed around the oblong orifice of the steering bowl, extending over a sufficient width to facilitate the assembly of the rack and steering column, with an inclination relative to the mean plane and connected via welding points for enhanced sealing and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the front side members are brought closer together to accommodate new wheel width and turning radius requirements, then the wheel width and turning radius requirements are met, but the width of the border around the oblong orifice in the steering bowl becomes insufficient
Solution Approach 1:
The border around the oblong orifice is segmented into two parts: the original border integrated with the steering bowl, and an additional annular flat piece that is separately attached to the border. This segmentation allows the annular flat piece to be added without requiring more space from the constrained border, thus resolving the contradiction between reduced overall dimensions and the need for sufficient border width.
Solution Approach 2:
The annular flat piece is nested onto the existing border structure, similar to a nested doll configuration. The annular flat piece fits over the border and is secured to it, effectively increasing the border width without requiring additional space that would conflict with the closer positioning of the front side members.
2Ease of operation
If the steering column is adjusted laterally as far to the left as possible to free up space for the front passenger, then passenger compartment comfort is improved, but the steering bowl finds itself stuck in the angle between the bulkhead and the side member
Solution Approach 1:
The sealing system is segmented into the original border structure and the additional annular flat piece with sealing element. This segmentation allows the sealing function to be enhanced without requiring the steering bowl to be repositioned, thus maintaining the optimized lateral adjustment of the steering column for passenger comfort while resolving the positioning constraint.
3Productivity
If the width of the border around the oblong orifice is reduced due to constraints, then the front side members can be brought closer together, but the assembly of the steering column and rack becomes less easy
Solution Approach 1:
The annular flat piece acts as an intermediary element between the rack joint and the steering bowl border. It provides an extended sealing surface that facilitates the assembly process, allowing the rack joint to be properly sealed and connected even when the original border width is reduced. This intermediary element maintains ease of manufacture while enabling the closer positioning of front side members.
Data Source
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AI summary
The invention relates to a front structure of a motor vehicle comprising: a bulkhead extending between an engine compartment and a passenger compartment; two front side members (18') connected to the bulkhead (12'); a steering ball joint (20') provided in the bulkhead (12') and projecting into the engine compartment, the steering ball joint (20') having a base and an oblong orifice (24') provided in the base and defining an edge (26') extending around the oblong orifice (24') facing the engine compartment; and a rack (34) installed in the engine compartment and a rack seal (42) designed to engage between the rack (34) and the steering ball joint (20'). The structure further comprises a planar annular part (50) surface mounted on said edge (26') and extending around the oblong orifice (24') in order to be able to extend the reception range of the rack seal (42).