Rack Steering Housing With Integrated Stop Face for Lower-Cost Assembly
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Solution Overview
Problem
The existing rack steering systems for motor vehicles are costly to manufacture due to the need for complex housing designs and separate stop elements that absorb forces, which increases production costs.
Innovation Solution
A one-piece steering gear housing with a direct stop face or support face that covers only partial circumferential segments allows for a simpler and cost-effective design, using a plastic injection molded housing cover and a separate stop element that can be made of metallic material with a similar coefficient of thermal expansion, and includes mounting arms for structural connection to the vehicle frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the steering gear housing is designed in two parts with separate stop elements to absorb forces, then the mechanical integrity and force absorption capability are improved, but the manufacturing complexity and production costs increase
Solution Approach 1:
The patent combines the stop element function directly into the steering gear housing by forming a stop face as an integral part of the housing structure. This eliminates the need for separate stop elements and reduces assembly complexity while maintaining force absorption capability through the integrated design.
Solution Approach 2:
The steering gear housing is designed to perform multiple functions: it provides structural support, seals the internal components, and incorporates the stop face for force absorption. This multi-functional design eliminates the need for separate dedicated stop elements, reducing part count and manufacturing complexity.
2Strength
If the steering gear housing is designed in two parts with separate stop elements, then the force absorption capability is improved, but the manufacturing costs increase
Solution Approach 1:
The stop face is integrated into the steering gear housing as a single molded part, eliminating the need for separate stop element components and their associated manufacturing and assembly costs. This integration reduces the total part count and simplifies the manufacturing process.
Solution Approach 2:
The patent changes the material and structural parameters of the housing to enable it to perform the stop function. By designing the housing with an integrated stop face that has appropriate geometric parameters and material properties, it can absorb forces without requiring separate metal stop elements.
3Stability of the object's composition
If the stop face extends over the full circumference, then the force distribution is improved, but the ease of assembly and sealing is worsened
Solution Approach 1:
The stop face is designed as a partial circumferential segment rather than a full circumferential structure. This segmentation allows the belt to pass through the housing while providing sufficient stop surface area for force absorption, balancing structural stability with assembly ease and sealing requirements.
Solution Approach 2:
The stop face is positioned locally at the appropriate location on the housing where force absorption is needed, rather than extending uniformly around the entire circumference. This local placement optimizes the force distribution where required while maintaining ease of assembly and sealing in other areas.
Data Source
AI summary
A rack steering system and a motor vehicle having such a rack steering system. The inventive rack steering system comprises a steering gear housing, a toothed rack, which extends through the steering gear housing, an electric motor, which is coupled to the toothed rack on a thread side of the steering gear housing via a ball screw to provide an axial force to the toothed rack, and two track rod links arranged at axial ends of the toothed rack. The steering gear housing is designed in one piece such that a drive insert opening is formed on the thread side of the steering gear housing for arrangement of the electric motor and a direct stop face for a track rod link or a support face for the arrangement and axial support of a separate stop element for a track rod link is also formed on this thread side.