Steer-by-Wire Bevel Gear Overload Protection
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Solution Overview
Problem
Traditional vehicle steering systems with mechanical linkages suffer from imprecise steering, high component wear, and bulky packaging, making them difficult to maneuver, especially in tight spaces and under external impact loads, which can degrade performance over time.
Innovation Solution
A steer-by-wire system with an electric motor coupled to a steering axle via a bevel gear set and a ball screw arrangement, featuring an overload protection mechanism that disengages the motor from impact loads using locking pins, eliminating mechanical linkages and reducing wear without additional sensors or control logic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mechanical linkages are used in steering systems, then structural simplicity is maintained, but steering precision deteriorates and component wear increases
Solution Approach 1:
The patent replaces traditional mechanical linkages (steering column, rack and pinion) with an electric motor-driven system. The motor couples directly to the steering axle via a bevel gear set and ball screw arrangement, eliminating intermediate mechanical components that cause wear and imprecision. This substitution of mechanical systems with an electromechanical system resolves the contradiction by achieving higher steering precision without the cumulative errors and wear of multiple mechanical joints.
Solution Approach 2:
The patent extracts and removes the steering column and its associated mechanical linkages from the steering system. By taking out these problematic mechanical components and replacing them with a direct electric motor coupling to the steering axle, the system achieves improved steering precision and reduced component wear while maintaining structural functionality.
2Reliability
If mechanical linkages are used to connect steering wheel to steering axle, then system simplicity is maintained, but component wear from external impact loads increases
Solution Approach 1:
The patent replaces the mechanical linkage chain (steering column, bearings, rack) that transmits external impact loads to the steering mechanism with an electric motor system. The motor and its direct coupling to the steering axle via bevel gears and ball screw isolates the steering mechanism from external impact loads, preventing the cumulative wear that would otherwise degrade components and reduce reliability.
Solution Approach 2:
The electric motor acts as an intermediary between the steering control system and the steering axle. This intermediary element (the motor with its bevel gear set and ball screw) decouples the steering mechanism from direct mechanical connection to the wheels, thereby protecting it from external impact loads that would otherwise cause wear and failure in traditional mechanical linkage systems.
3Ease of operation
If steering assist systems with electric motors are used, then steering effort is reduced, but packaging space requirements increase
Solution Approach 1:
The patent merges the functions of the steering assist motor, steering actuator, and steering mechanism into a single integrated assembly. The electric motor is directly coupled to the steering axle, combining what would traditionally be separate components (motor, rack, pinion, steering column) into one compact unit. This merging eliminates the need for additional packaging space for separate mechanical linkages while maintaining the steering assist function.
Solution Approach 2:
The patent extracts and eliminates the steering column and its associated mechanical components from the system. By removing these bulky intermediate components and using a direct electric motor coupling to the steering axle, the system achieves reduced packaging space requirements while maintaining ease of operation through electric steering assist.
4Manufacturing precision
If traditional steering systems are used, then mechanical robustness is maintained, but turning precision at low speeds deteriorates
Solution Approach 1:
The patent replaces the mechanical steering column and rack system with an electric motor-driven steering system. This substitution enables precise control of steering force and position through electronic control, achieving superior turning precision at low speeds compared to traditional mechanical systems. The electric motor provides controlled torque delivery without the play and imprecision inherent in mechanical linkages.
Solution Approach 2:
The patent changes the control parameter from purely mechanical force transmission to electrically controlled torque delivery. By using an electric motor with electronic control, the system can precisely modulate steering force and position, achieving high turning precision at low speeds while maintaining the ability to provide adequate steering force when needed.
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 solution provides precise steering, reduces human effort, and extends the lifespan of components by mitigating wear from external impacts, while minimizing packaging size and improving vehicle efficiency.
Implementation Method 1
an electric motor coupled to a steering axle via a bevel gear set, where a rotor of the motor is perpendicular to the steering axle, and the bevel gear set comprises a first bevel gear and a second bevel gear
Implementation Method 2
an electric motor coupled to a steering axle via a bevel gear set, where a rotor of the motor is perpendicular to the steering axle
Implementation Method 3
an overload protection arrangement, where the second bevel gear is normally coupled to a ball screw nut via a plurality of locking pins, the plurality of locking pins disengaging from the second bevel gear and allowing slipping of the ball screw nut in response to an external impact load acting on the ball screw nut exceeding a threshold
Data Source
AI summary
Methods and systems are provided for a steer-by-wire system. In one example, a steer-by-wire system comprises an electric motor coupled to a steering axle via a bevel gear set, where a rotor of the electric motor is perpendicular to the steering axle, and the bevel gear set comprises a first bevel gear and a second bevel gear. The steer-by-wire system includes an overload protection arrangement, where the second bevel gear is normally coupled to a ball screw nut via a plurality of locking pins, the plurality of locking pins disengaging from the second bevel gear and allowing slipping of the ball screw nut in response to an external impact load acting on the ball screw nut exceeding a threshold.