Steering Knuckle Assembly Weight Reduction via Segmented Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing steering knuckles for wheeled vehicles are either heavy due to being single-piece cast items or complex in design as fabricated multi-piece components, which can lead to weight and manufacturing inefficiencies.
Innovation Solution
A steering knuckle assembly comprising a knuckle body with a generally vertical face and an upper yolk arm, where the spindle is secured by circular welds, allowing for a balanced design that reduces weight and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If single-piece cast steering knuckles are used, then structural integrity is improved, but weight increases
Solution Approach 1:
The steering knuckle is divided into multiple separate components including a first piece with a vertical face, a second piece forming an upper yoke arm, and a spindle. These components are individually manufactured and then joined together through welding to form the complete steering knuckle assembly, allowing weight reduction while maintaining structural integrity through proper joint design
2Weight of moving object
If fabricated multi-piece steering knuckles are used, then weight is reduced, but device complexity increases
Solution Approach 1:
The patent combines multiple components (first piece, second piece, and spindle) into a integrated steering knuckle assembly where the components are joined through welding. The upper yoke arm is formed as part of the second piece, merging multiple functional elements into a cohesive unit that reduces overall complexity while maintaining weight advantages
3Weight of moving object
If fabricated multi-piece steering knuckles are used, then weight is reduced, but manufacturing efficiency decreases
Solution Approach 1:
The first piece and second piece are prepared in advance with predetermined configurations including the vertical faces and yoke arm structures. The spindle is also pre-formed with the upper end configuration. These preliminary preparations enable efficient assembly through direct welding operations, improving manufacturing efficiency while maintaining the weight benefits of the fabricated multi-piece design
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 solution provides a lightweight and efficient steering knuckle assembly that balances weight reduction with structural integrity, improving the overall performance and manufacturing efficiency of vehicle steering systems.
Implementation Method 1
the spindle being secured to the spindle bore by at least one circular weld along a perimeter of the spindle
Data Source
Figure 1
Figure 2~6
Figure 7~9
AI summary
A steering knuckle is provided for use in association with a vehicle steering assembly. The steering knuckle includes a knuckle body having a generally vertical face and an upper yolk arm having a generally vertical face. The generally vertical faces of the steering knuckle and the upper yolk arm are connected to each other. The generally vertical face of the upper yolk arm includes a camshaft bore extending therethrough and configured to receive a camshaft. The generally vertical face of the knuckle body may be welded to a spindle, with a portion of the spindle being cut away to allow for a complete circular weld between the knuckle body and the spindle.