Segmented Sheet Metal Steering Arm for Commercial Vehicles
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Solution Overview
Problem
Steering arms for commercial vehicles are typically expensive and heavy due to their solid, cast or forged construction, which is not cost-effective or lightweight.
Innovation Solution
A steering arm design utilizing three sheet metal elements, including a bent third element with U-shaped sections for connection to the wheel hub and flat first and second elements, with plug and hook connections, and reinforcement walls, allowing for a lightweight, inexpensive, and material-saving construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid cast or forged construction is used for steering arm, then strength and reliability are improved, but weight and manufacturing cost increase
Solution Approach 1:
The steering arm is divided into multiple sheet metal elements (first, second, and third sheet metal elements) that are interconnected through weld seams rather than being a solid monolithic structure. This segmentation reduces material usage and weight while maintaining structural integrity through the distributed network of connected elements.
Solution Approach 2:
The invention uses composite construction combining multiple sheet metal elements with different geometries (flat elements and bent U-shaped elements) to create a lightweight yet strong structure. The combination of these different metal element types provides both weight reduction and structural strength.
2Reliability
If solid cast or forged construction is used for steering arm, then structural integrity is improved, but manufacturing cost increases
Solution Approach 1:
The steering arm is segmented into multiple manufacturable sheet metal components that can be produced using cost-effective sheet metal forming processes rather than expensive casting or forging operations. These segmented parts are then assembled through welding, which is generally more cost-effective for complex geometries.
Solution Approach 2:
The invention changes the manufacturing parameters from solid cast/forged processes to sheet metal forming and welding processes. This parameter change enables production of complex lightweight structures at lower manufacturing costs while maintaining structural integrity through proper weld design.
3Strength
If solid cast or forged construction is used for steering arm, then strength is improved, but material usage increases
Solution Approach 1:
By segmenting the steering arm into multiple sheet metal elements connected by weld seams, the design uses only the necessary amount of material for each functional section rather than requiring solid material throughout the entire structure. This reduces overall material consumption while maintaining required strength at critical locations.
Solution Approach 2:
The sheet metal elements are designed with varying thicknesses and geometries to provide local quality - thicker sections where strength is required and thinner sections where less strength is needed. This optimizes material usage by concentrating material only where structurally necessary.
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
The design results in a steering arm that is both inexpensive and lightweight while maintaining sufficient stiffness, reducing material usage and manufacturing costs while ensuring structural integrity.
Implementation Method 1
The third sheet metal element 3 is welded to the first sheet metal element 1 and the second sheet metal element 2
Data Source
Figure 1
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AI summary
The invention relates to a track rod S for a steering mechanism for a motor vehicle, preferably a commercial vehicle. The track rod S comprises a first sheet metal element 1, a second sheet metal element 2, and a third sheet metal element 3. The third sheet metal element 3 is welded to the first sheet metal element 1 and the second sheet metal element 2 and preferably has contact surfaces K1, K2 for connection to a wheel hub.