Integrated Steering Knuckle Structure for Lower Weight and Strength
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Solution Overview
Problem
Existing steering knuckles in automotive suspension systems have a complex structure with multiple connection parts, leading to increased weight and complexity, which can compromise mechanical properties and efficiency.
Innovation Solution
A steering knuckle design integrating a rod part, a disc part, and ear parts with a pulling arm and steering arm, where the arms are directly connected to the disc part, reducing the number of connection parts and simplifying the structure, achieved through a forging process that forms the arms and disc from a billet, optimizing material distribution for reduced weight and enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional steering knuckles use multiple separate connection parts to attach suspension and steering components, then the structure provides adequate strength and connection reliability, but the weight increases and structural complexity increases
Solution Approach 1:
The patent integrates multiple connection parts into a single integrated steering knuckle structure. The suspension arm connection portion, inner tie rod connection portion, and outer tie rod connection portion are merged into one monolithic component formed by forging, eliminating the need for separate connection parts and reducing overall weight while maintaining structural strength.
Solution Approach 2:
The integrated steering knuckle performs multiple functions simultaneously: it serves as the suspension arm connection point, inner tie rod connection point, outer tie rod connection point, and wheel hub mounting point all in one component. This multi-functionality reduces the number of parts needed while maintaining all necessary mechanical connections.
2Adaptability or versatility
If traditional steering knuckles use multiple separate connection parts, then adequate connection points are provided, but the structural complexity and number of components increases
Solution Approach 1:
Multiple connection functions are merged into a single integrated structure. The steering knuckle simultaneously provides suspension arm connection, inner tie rod connection, outer tie rod connection, and wheel hub mounting capabilities without requiring separate components for each function.
Solution Approach 2:
The steering knuckle is designed as a universal component that performs all connection functions in one piece, eliminating the need for multiple specialized parts while maintaining full adaptability for suspension and steering connections.
3Strength
If multiple separate connection parts are used in traditional steering knuckles, then adequate strength at connection points is achieved, but manufacturing complexity and assembly difficulty increases
Solution Approach 1:
The patent combines all connection portions into a single forged component, eliminating the need for separate manufacturing and assembly of multiple parts. The integrated structure is produced in one forging operation, significantly simplifying manufacturing while maintaining connection strength.
Data Source
AI summary
A steering knuckle, including a rod part, a disc part, an ear part including a first ear and a second ear. The rod part and the ear part are disposed on two sides of the disc part, respectively. The first ear is longer than the second ear. The first ear and the second ear each include a pin hole; the connection line of two pin holes of the first ear and the second ear is perpendicular to the axis of the rod part. The first ear extends parallel to the axis of the rod part in the direction away from the disc part to form a pulling arm configured to connect to a steering drag link. The second ear extends perpendicularly to the axis of the rod part and perpendicularly to the connection line of the two pin holes to form a steering arm configured to connect to a steering tie rod.