Progressive Steering Gear Serration for Harmonious Feedback
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Solution Overview
Problem
Existing progressive steering systems face challenges in providing a harmonious and cost-effective driving experience due to limitations in tooth geometry optimizations over decades, which affect steering precision and manufacturing efficiency.
Innovation Solution
The use of serrated components with uniformly angled prongs, where at least 50% of prongs have symmetrical first and second flank angles corresponding to a reflection at the center plane, replaces traditional teeth in rack-and-pinion steering systems, enhancing steering harmony and allowing for inexpensive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional tooth geometry optimizations from decades of rack-and-pinion steering systems are used, then steering precision is maintained, but manufacturing cost increases and steering harmony deteriorates
Solution Approach 1:
The patent applies asymmetry by using symmetrical flank angles (identical angles on both sides of the prong) which is actually a form of symmetry principle. This symmetrical design simplifies manufacturing while improving steering harmony and feedback, directly resolving the contradiction between manufacturing ease and steering quality.
Solution Approach 2:
The patent changes the geometric parameters of the prongs by standardizing the flank angles to be identical on both sides. This parameter change simplifies the manufacturing process and reduces costs while simultaneously improving the steering experience through more harmonious force distribution.
2Manufacturing precision
If complex tooth geometry optimizations are implemented, then steering precision improves, but manufacturing complexity increases
Solution Approach 1:
The patent simplifies the tooth geometry by changing the parameters to use identical flank angles on both sides of each prong. This reduces the geometric complexity from asymmetric multi-angle designs to symmetric single-angle designs, making manufacturing more precise and easier while maintaining steering precision.
Solution Approach 2:
The patent applies homogeneity by making all prongs have the same flank angle configuration. This uniformity across all prongs simplifies manufacturing processes and ensures consistent steering precision without requiring complex varying geometries.
3Measurement precision
If asymmetric prong angles are used, then steering precision improves, but manufacturing cost increases
Solution Approach 1:
The patent actually applies symmetry (not asymmetry) by using identical flank angles on both sides of prongs. This symmetrical approach improves steering feedback quality through harmonious force distribution while simultaneously reducing manufacturing costs by simplifying the manufacturing process.
Solution Approach 2:
The patent changes the angle parameters to be identical on both sides of each prong, which improves steering feedback through more uniform force application while reducing manufacturing costs by eliminating the need for complex asymmetric angle measurements and machining.
Data Source
AI summary
A serrated component (10) for use in a progressive steering gear includes first and second inclined prong ramps (14, 16). The first and second inclined prong ramps (14, 16) include a plurality of prongs (20, 50) each having a first flank angle and a second flank angle with respect to a center plane (48) that extends normal to a longitudinal direction (34) of the serrated component (10). For at least 50% of the prongs (20, 50) of the plurality of prongs (20, 50), the first flank angles have a single first angle value and the second flank angles have a single second angle value, the first angle value corresponding to a reflection of the second angle value at the center plane (48). The invention further comprises a progressive steering gear, a method of manufacturing a serrated component, and a method of manufacturing a steering gear.