Modular Knuckle Apparatus with Segmented Brackets
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Solution Overview
Problem
Conventional knuckle apparatuses for vehicle suspension systems are one-piece members, making it necessary to redesign and manufacture new knuckles for changes in suspension geometries or brake systems, which is inefficient in terms of weight and material usage, and increases manufacturing costs.
Innovation Solution
A modular knuckle apparatus with a bearing device and multiple brackets connected through an assembly end portion, allowing for the use of different materials for each suspension component, enabling substitution of specific parts without redesigning the entire knuckle, and incorporating recessed grooves to reduce weight and improve fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece knuckle is used, then structural simplicity is maintained, but weight optimization and material selection are limited
Solution Approach 1:
The knuckle is divided into multiple separate brackets (first bracket, second bracket, third bracket) that are coupled together through the assembly end portion of the bearing device. This segmentation allows each bracket to be manufactured from different materials optimized for its specific function, enabling weight reduction while maintaining structural integrity.
Solution Approach 2:
Different brackets can be manufactured from different materials (e.g., aluminum alloy for non-critical brackets, steel for load-bearing brackets) based on their specific functional requirements. This composite material approach optimizes the overall knuckle weight while ensuring each component has the appropriate material properties for its intended use.
2Ease of manufacture
If a one-piece knuckle is used, then manufacturing process is simplified, but adaptability to component changes is reduced
Solution Approach 1:
The modular bracket structure allows individual brackets to be independently manufactured and assembled. When suspension geometries or brake systems need to be changed, only the specific bracket requiring modification needs to be redesigned and manufactured, while other brackets remain unchanged. This significantly improves adaptability compared to one-piece knuckles where any change requires complete redesign.
Solution Approach 2:
The standardized coupling interface through the bearing device's assembly end portion allows different brackets to be interchangeably mounted. This universal coupling mechanism enables flexible substitution of suspension components and brake systems without affecting the overall knuckle structure, enhancing versatility while maintaining manufacturing efficiency for standard components.
3Weight of moving object
If different materials are used for different knuckle portions, then weight is optimized, but manufacturing complexity increases
Solution Approach 1:
By dividing the knuckle into separate brackets, each can be manufactured from the most appropriate material for its specific function. This segmentation simplifies the material selection process compared to a one-piece design, as each bracket can be independently optimized without requiring complex multi-material manufacturing processes like injection molding with inserts or differential heat treatment of a single component.
Data Source
AI summary
A knuckle apparatus for a vehicle suspension system, may include a bearing device having an assembly end portion protruding and extending from a center thereof; and a knuckle device having a plurality of brackets connected to a suspension system component, the brackets being coupled through the assembly end portion.