Steering Pinion Segmented Design for Material Reduction
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Solution Overview
Problem
Conventional steering pinions are designed as one-piece components, leading to high material usage and production costs due to complex machining requirements, particularly in the connection section, which needs to be turned or formed to a smaller diameter.
Innovation Solution
The steering pinion is divided into two separate components: a toothed part with a toothed section and a connecting part with a connection section, which are pressed together in a torque-proof manner, allowing for optimized material usage and simplified production by using different materials for each part, with the toothed part made from high-quality solid material and the connecting part made from a lower-quality, hollow material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a steering pinion is manufactured as a one-piece component from high-strength material, then reliability and service life are improved, but material usage and manufacturing costs increase
Solution Approach 1:
The steering pinion is divided into two separate components: a toothed part made from high-strength solid material and a connecting part made from lower-grade hollow material. This segmentation allows each component to be optimized for its specific function, reducing overall material usage while maintaining reliability where needed.
Solution Approach 2:
Different materials and structures are used in different parts of the steering pinion. The toothed section uses high-strength solid material to withstand operational stresses, while the connecting section uses lower-grade hollow material where high strength is not required, optimizing material distribution locally.
2Strength
If a conventional one-piece steering pinion is manufactured, then structural integrity is ensured, but manufacturing complexity and costs increase due to turning and forming operations
Solution Approach 1:
The steering pinion is segmented into a toothed part and a connecting part that are pressed together. This eliminates the need for complex turning and forming operations on a single piece, as each component can be manufactured more simply and then assembled through pressing.
Solution Approach 2:
The toothed part and connecting part are combined through a pressing operation to form the complete steering pinion. This merging of components after simplified manufacturing processes achieves the same structural integrity as a one-piece component but with reduced manufacturing complexity.
3Manufacturing precision
If the connecting section is turned down to smaller diameter in conventional manufacturing, then proper fit is achieved, but machining costs increase
Solution Approach 1:
The steering pinion is divided into components with different diameters that are pressed together. The connecting part can be supplied directly in the desired diameter without requiring turning operations, while the toothed part maintains its larger diameter, eliminating the need to turn down the connecting section.
Solution Approach 2:
The design parameters of the components are changed to allow the connecting part to be manufactured at its final desired diameter from the start, eliminating the need for subsequent turning operations and reducing machining costs.
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 design reduces material usage and production costs while ensuring a durable, play-free connection that withstands operational stresses, enhancing the steering pinion's torsional strength and service life.
Implementation Method 1
the toothed part and the connecting part are pressed together in a rotationally fixed manner
Implementation Method 2
pressed together in a torque-proof manner
Data Source
Figure 1
Figure 2~4
Figure 5~9
AI summary
The invention relates to a steering pinion (1), in particular as a coupling connection between a steering shaft (3) and a gear rack (4) of a motor vehicle, wherein the steering pinion (1) has a toothed section (18) for meshing with a gear rack (4) and a connection section (10) for connecting to a steering shaft (3), wherein a toothed part (11) having the toothed section (18) and a connection part (12) having the connection section (10) are provided and wherein the toothed part (11) and the connection part (12) are pressed together in a rotationally fixed manner.