Steering Knuckle Weight Reduction via Lattice Support Rib
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Solution Overview
Problem
Existing pivot bearings for motor vehicle wheel suspensions are excessively heavy due to their solid design, which compromises weight savings while maintaining strength requirements.
Innovation Solution
A lightweight, filigree pivot bearing design featuring machined domes for wheel bearing fastening, continuous openings for weight reduction, and a one-piece cast construction using materials like spheroidal graphite iron or aluminum, with a support web merging into the steering arm and strategically placed openings to minimize material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid design is used for the pivot bearing, then strength and structural integrity are maintained, but weight increases significantly
Solution Approach 1:
The support rib is segmented into a lattice structure composed of multiple struts arranged in triangular patterns, rather than being a solid continuous structure. This segmentation reduces material usage and weight while maintaining structural integrity through the geometric stability of the triangular lattice configuration.
Solution Approach 2:
The lattice structure of the support rib provides locally optimized strength where needed, with denser strut arrangements in high-stress areas and sparser arrangements in lower-stress regions. This local quality variation maintains overall structural integrity while minimizing weight throughout different zones of the pivot bearing.
2Weight of moving object
If material is removed to reduce weight, then weight decreases, but structural strength may be compromised
Solution Approach 1:
The lattice structure is pre-designed with struts positioned and dimensioned to anticipate and withstand expected load paths before the pivot bearing is assembled and subjected to operational forces. This preliminary structural configuration ensures that material is removed only from locations that will not compromise strength under predicted service conditions.
Solution Approach 2:
The support rib incorporates curved and angled strut arrangements rather than straight rigid members, allowing loads to be distributed more evenly through the lattice structure. The curved geometry provides structural efficiency by redirecting stress paths while using less material compared to solid straight members.
Data Source
Figure 1~2
Figure 3~4
AI summary
Swivel bearing for a wheel suspension, in particular for a front axle of a motor vehicle, comprising a wheel bearing receptacle, at least one upper and lower brake carrier connection, a control arm connection, a steering arm, a damper receptacle, a support rib, wherein the support rib extends from one side of the damper receptacle and the upper brake carrier connection is arranged on the support rib, and a support web, wherein the support web extends from the other side of the damper receptacle, wherein the swivel bearing has at least one opening, wherein the opening is arranged in the area between the wheel bearing receptacle and the damper receptacle, wherein the opening is divided by a strut extending from the damper receptacle or the support web to the wheel bearing receptacle.