Steering Knuckle Cap Integrated Sensor for Wheel Alignment
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Solution Overview
Problem
Conventional steering systems face challenges in accurately measuring and maintaining wheel turn and toe angles, leading to potential misalignment and wear, which can affect vehicle performance and require frequent maintenance.
Innovation Solution
A wheel-end assembly with an integrated angular position sensor, including a knuckle with a kingpin bore, a kingpin, and a knuckle cap assembly coupled with a sensor to measure the kingpin's position, allowing for direct measurement of rotational and axial positions, enabling identification of misalignment and wear, and facilitating precise adjustment of turn and toe angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional steering systems use mechanical linkages to control wheel direction, then the steering system can provide desired wheel turn angle, but the system cannot directly measure turn angle and toe angle during operation
Solution Approach 1:
The sensor is integrated within the knuckle cap assembly, which is itself part of the wheel-end assembly. The magnet is coupled to the kingpin, and the sensor is positioned within the knuckle cap to measure the magnet's position, creating a nested configuration where measurement components are embedded within existing structural elements rather than adding external measurement devices
Solution Approach 2:
The knuckle cap assembly serves multiple functions: it provides structural support for the kingpin, houses the sensor, and enables direct measurement of turn angle and toe angle. This multi-functional design allows the same component to serve both mechanical and measurement purposes, reducing the need for separate measurement systems
2Reliability
If steering system components are not monitored, then the system structure remains simple, but components become misaligned or unfit for service requiring frequent maintenance
Solution Approach 1:
The sensor provides continuous measurement feedback of the kingpin's position relative to the knuckle cap assembly, enabling real-time monitoring of turn angle and toe angle. This feedback mechanism allows the system to detect misalignment and wear conditions as they develop, enabling timely maintenance before components become unfit for service
Solution Approach 2:
By implementing continuous measurement and monitoring capabilities through the integrated sensor, the system can identify potential misalignment and wear issues before they lead to component failure. This preliminary detection allows maintenance to be performed proactively rather than reactively, reducing downtime and preventing further damage
3Manufacturing precision
If additional linkages are added to implement Ackermann steering geometry, then steering accuracy improves, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical linkages with an electronic measurement and control system. The sensor measures the kingpin's position to determine turn angle and toe angle, and this data can be used by a control system to implement Ackermann steering geometry through electronic control rather than mechanical linkages, reducing structural complexity while maintaining steering precision
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
Enables accurate measurement and adjustment of wheel turn and toe angles, improving vehicle stability, reducing tire wear and noise, and allowing for accurate implementation of Ackermann steering geometry without additional linkages, while providing redundancy and increased accuracy in autonomous vehicles.
Implementation Method 1
a magnet is coupled with an end of the kingpin adjacent to the sensor
Data Source
AI summary
A wheel-end assembly for a vehicle enabling the direct measurement of the wheel-end position. The wheel-end assembly includes a knuckle having a kingpin bore and a kingpin disposed within the kingpin bore. The knuckle is at least partially rotatable about a longitudinal axis of the kingpin. A knuckle cap assembly is coupled with the kingpin bore adjacent to an end of the kingpin. In addition, a sensor is coupled with the knuckle cap assembly which measures a position of the kingpin relative to the sensor.