Push Rod Polygonal Guide Finishing for Low-Friction Torque Support
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Solution Overview
Problem
Existing motor vehicle steering systems face challenges in stabilizing torque support for push rods over their service life while minimizing friction, as conventional solutions are expensive and inefficient.
Innovation Solution
The method involves producing a push rod with a spindle section and a guide section featuring a polygonal profile, where the final shape of the polygonal profile is achieved through burnishing, reducing friction and ensuring stability by creating a work-hardened surface with low surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If roller-guided torque supports are used, then torque support stability is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive roller-guided torque supports with a cost-effective sliding guide made of polygonal-profiled push rod sections. The sliding guide uses simple sliding contact instead of complex roller mechanisms, significantly reducing manufacturing costs while maintaining adequate torque support functionality throughout the service life
Solution Approach 2:
The patent substitutes the mechanical roller guidance system with a simplified sliding guidance mechanism. By using a polygonal profile on the push rod that slides within a corresponding guide, the complex roller-based torque support is replaced with a simpler sliding contact system that achieves the same functional goal at lower cost
2Ease of manufacture
If sliding guide is used instead of roller guide, then manufacturing cost is reduced, but friction increases
Solution Approach 1:
The patent changes the surface parameters of the sliding guide by applying specific surface treatments (such as coating or heat treatment) to reduce the coefficient of friction. By modifying surface properties like roughness and material composition, the sliding guide achieves low friction characteristics comparable to roller guidance while maintaining the cost advantages of sliding contact
Solution Approach 2:
The patent introduces an intermediary layer or coating on the sliding surfaces of the polygonal profile. This intermediate layer (such as a lubricating coating or low-friction material layer) mediates the contact between sliding surfaces, reducing direct metal-to-metal friction and energy losses while allowing the simple sliding guide structure to function efficiently
3Loss of energy
If smooth rolling is used to produce final polygonal profile, then surface roughness is reduced and friction is minimized, but manufacturing complexity increases
Solution Approach 1:
The patent applies smooth rolling as a final finishing operation after the polygonal profile has been established by less complex forming processes. By performing the smooth rolling operation last, the process achieves low surface roughness and minimal friction without requiring complex equipment for the entire manufacturing sequence, as the bulk shaping is completed by simpler methods first
4Measurement precision
If minimal twist angles are maintained, then steering precision is improved, but torque support requirements increase
Solution Approach 1:
The patent employs composite construction or material combinations in the push rod and guide sections to achieve high structural stiffness and strength. By using materials or structures that combine different properties (such as high-strength alloys, composite materials, or optimized cross-sections), the system can resist torque-induced twisting with minimal angular deviation while distributing the torque support requirements across the composite structure
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
This approach allows for minimal rotation angles and reduced friction losses, enhancing the durability and stability of the torque support, thereby improving the steering system's performance.
Implementation Method 1
a cold-worked surface can be produced on the guide section by smooth rolling, resulting in a high durability of the push rod
Implementation Method 2
creating a work-hardened surface with low surface roughness
Implementation Method 3
The push rod (10) is smoothed in the region of this preform by rolling to obtain the final shape of the polygonal profile (12a)
Data Source
Figure 1
Figure 2~3
Figure 2
AI summary
In a method for manufacturing a push rod (10) for a motor vehicle steering system (1), wherein the push rod (10) has at least one spindle section (11) with a threaded spindle (11a) and a guide section (12) with a polygonal profile (12a) for sliding guidance and anti-rotation on a stationary guide device of the motor vehicle steering system (1), it is provided that the final shape of the polygonal profile (12a) is produced on the guide section (12) by smooth rolling.