Vehicle Power Steering Rack Housing Segmentation
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Solution Overview
Problem
The complex shape of the rack housing in power steering apparatuses leads to weak portions and cracks in the main core during manufacturing, increasing costs, difficulty in maintenance, and the complexity of manufacturing processes and equipment.
Innovation Solution
A power steering apparatus design that simplifies the rack housing shape by separately manufacturing and coupling components, reducing the number of slide cores and using pin slides instead of slide cores, which strengthens the main core and reduces manufacturing time and equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the rack housing has a complex shape to accommodate steering components, then the functional requirements are met, but the main core weakens and cracks during manufacturing
Solution Approach 1:
The rack housing is divided into multiple separate components (rack housing body, cover, and side panels) that are manufactured independently and then assembled together. This segmentation allows each component to have a simpler shape that strengthens the main core while collectively achieving the required functional complexity through assembly.
2Adaptability or versatility
If multiple slide cores are used to manufacture the complex rack housing shape, then the functional requirements are met, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The manufacturing process is segmented into separate casting operations for each component (rack housing body, cover, side panels), each using simpler molds with fewer slide cores. The complexity is then resolved through assembly operations rather than attempting to create the entire complex shape in a single molding process.
3Adaptability or versatility
If multiple slide cores are used for the rack housing, then the complex shape is achieved, but the manufacturing cost increases
Solution Approach 1:
By segmenting the rack housing into separate components manufactured with simpler molds, the patent reduces the number of expensive slide cores needed. The assembly process allows for standardized, cost-effective manufacturing of individual parts that can be produced using more economical molding techniques.
4Adaptability or versatility
If the rack housing structure is complex, then it accommodates all necessary components, but the equipment size becomes large
Solution Approach 1:
The separate components (cover, side panels) are designed to nest or attach to the main rack housing body in a compact arrangement. This nesting approach allows the components to be manufactured and stored separately, then assembled into the final configuration without requiring excessively large equipment or storage space.
Data Source
AI summary
The present disclosure relates to a power steering apparatus of a vehicle that includes: a rack housing configured to surround a rack bar and having an opening portion formed at one side thereof through which a steering shaft passes; a torque sensor cover that has a torque sensor therein and has a communicating hole formed therein through which the steering shaft passes and a first penetration portion having a first through-hole formed therein through which the fastening member passes; and a cover connecting member that has an insertion portion and a second penetration portion in order to connect the rack housing and the torque sensor cover, the insertion portion having an insertion hole formed therein where the opening portion is inserted and coupled and the second penetration portion having a second through-hole that is formed therein to correspond to the fastening hole and through which the fastening member passes.