Hemispherical Bushing Assembly for Steering Misalignment Compliance
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Solution Overview
Problem
Existing bushing assemblies in steering systems face issues with increased friction due to misalignment, requiring complex assemblies, high costs, and sensitivity to frame misalignment, which complicates manufacturing and vehicle handling performance.
Innovation Solution
A bushing assembly with a concave inner surface and a metal insert member having a convex interface surface that is pivotable, allowing for misalignment compliance and reducing assembly complexity through a single assembly step, using a threaded aperture and bore alignment to prevent binding and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a full soft mount bushing assembly is used, then misalignment compliance is improved, but device complexity and cost increase due to requiring two steel pieces overmolded with rubber and dual press assembly
Solution Approach 1:
The bushing assembly is divided into distinct functional segments: a hard mount body providing structural support and a separate hemispherical compliance feature that accommodates misalignment. This segmentation allows each component to be optimized for its specific function while simplifying the overall assembly process.
Solution Approach 2:
The compliance feature is integrated directly into the hard mount bushing assembly, merging the misalignment accommodation function with the structural mounting function. This eliminates the need for separate compliance components and reduces assembly steps while maintaining misalignment compliance.
2Adaptability or versatility
If a hemispherical washer design is employed, then misalignment compliance is improved, but device complexity and cost increase due to requiring three pieces and manual assembly
Solution Approach 1:
The hemispherical compliance feature is merged into a single integrated bushing assembly that can be installed using standard press-fit methods, eliminating the need for manual assembly of multiple separate pieces while maintaining misalignment compliance.
3Device complexity
If a hard mount bushing assembly is used, then device complexity is reduced, but sensitivity to frame misalignment increases causing binding and friction
Solution Approach 1:
The bushing assembly is segmented into a rigid mount body and a separate hemispherical compliance element, allowing the majority of the structure to remain simple while isolating the misalignment accommodation function to a specific geometric feature.
Solution Approach 2:
A hemispherical surface is incorporated into the bushing assembly to provide compliance. The curved spherical geometry allows for multi-directional movement and accommodation of frame misalignment without binding, reducing friction while maintaining a relatively simple overall structure.
4Device complexity
If a through bolt design is used, then device complexity is reduced, but sensitivity to frame misalignment increases and additional assembly steps are required at the OEM plant
Solution Approach 1:
The hemispherical compliance feature is integrated into the bushing assembly, providing misalignment compliance without requiring additional assembly steps at the OEM plant. The spherical geometry inherently accommodates frame misalignment while maintaining a simple overall design.
Data Source
AI summary
A bushing assembly includes a bushing housing having an inner surface that is non-planar. The bushing assembly also includes an insert member having an interface surface in contact with the inner surface of the bushing housing, wherein the interface surface comprises a non-planar geometry corresponding to the inner surface of the bushing housing.