Steering Gear Cover and Bearing Part for Lightweight Load Support
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Solution Overview
Problem
Existing electric steering systems for vehicles face challenges in optimizing the design of the gear cover and bearing part, which can lead to inefficient use of materials and potential deformation under high forces.
Innovation Solution
The steering system separates the gear cover and bearing part into distinct components, allowing for optimized material selection and configuration. The gear cover is designed to be lightweight and made from materials like plastic, while the bearing part is made from a stronger material like steel. The gear cover is fixed via a latching connection without screws, and it features a reinforcing structure, such as a honeycomb design, to enhance support during high-force operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the gear cover and bearing part are integrated into a single component, then the structural complexity is reduced, but the gear cover must be made from high-strength materials to withstand bearing forces, increasing weight and material cost
Solution Approach 1:
The patent divides the integrated component into two separate components: a gear cover and a bearing part. The bearing part is designed to withstand bearing forces while the gear cover can be made from lighter materials, thus reducing overall weight while maintaining structural integrity.
Solution Approach 2:
The bearing part is given local high-strength properties where it contacts the transmission rod to handle bearing forces, while the gear cover uses different material properties suitable for its specific function, optimizing material usage and reducing weight.
2Weight of moving object
If the gear cover is made from lightweight materials like plastic, then weight is reduced, but the gear cover may deform under high forces during maximum steering lock
Solution Approach 1:
The bearing part acts as an intermediary component between the transmission rod and the gear cover. It absorbs and withstands the high bearing forces, protecting the lightweight gear cover from direct exposure to these forces and preventing deformation.
Solution Approach 2:
The bearing part is positioned in advance to cushion and absorb high forces before they can reach the gear cover, preventing deformation of the lightweight gear cover material during extreme operating conditions.
3Strength
If the gear cover is made from high-strength materials to withstand high forces, then strength is improved, but the weight and material cost increase
Solution Approach 1:
The patent segments the load-bearing function from the gear cover and assigns it to the bearing part. This allows the gear cover to be made from lightweight materials while the bearing part uses high-strength materials, optimizing the strength-to-weight ratio.
Solution Approach 2:
High-strength materials are applied locally only where needed (in the bearing part), while the gear cover uses lighter materials appropriate for its specific function, avoiding unnecessary weight and material cost throughout the entire assembly.
4Strength
If screws are used to fix the gear cover, then the connection strength is improved, but the manufacturing complexity and assembly time increase
Solution Approach 1:
The bearing part and gear cover are designed to self-align and connect through their geometric features during assembly, eliminating the need for additional fastening operations with screws and reducing manufacturing complexity.
Data Source
AI summary
A steering system for a vehicle includes a transmission cover on a steering gear housing. The cover is arranged adjacent to a bearing part. The side surface of the bearing part facing the transmission cover forms a support surface for the transmission cover.