Steering Rack Segment Hardening for Simpler Rack Production
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Solution Overview
Problem
The existing production methods for steering gear racks are complex and time-intensive, requiring separate processing steps for hardened segments, which complicates the handling and machining of steel components.
Innovation Solution
A method involving continuous hardening and heat treatment of raw material pieces, allowing for the production of hardened semi-finished segment products that can be cut to length, reducing the need for individual segment processing and simplifying the production process by integrating hardening and machining steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate segments are processed individually through thermal hardening and treatment, then material properties can be optimized for specific functional regions, but the production process becomes complex and time-intensive
Solution Approach 1:
The raw material is divided into multiple segments along its length, with each segment receiving different thermal hardening and treatment parameters. This allows optimization of material properties for specific functional regions (toothed segment, shaft segment, transition segments) while processing all segments in a single continuous operation, reducing overall process complexity
Solution Approach 2:
Different regions of the rack receive different thermal treatments to create locally optimized material properties. The toothed segment receives different hardening parameters than the shaft segment or transition segments, allowing each region to have the specific mechanical properties needed for its functional requirements
2Manufacturing precision
If separate segments are processed individually through thermal hardening and treatment, then targeted material design can be implemented, but handling and machining of individual segments becomes cumbersome
Solution Approach 1:
Multiple segments are kept connected as part of a single continuous raw material piece during the thermal hardening and treatment process. This combining approach allows targeted material design for each segment while avoiding the handling and machining complexities of completely separate segments, as they remain positioned relative to each other throughout processing
3Manufacturing precision
If multiple separate segments are processed individually, then functional regions can be optimized, but production time increases significantly
Solution Approach 1:
The thermal hardening and treatment process operates continuously on the entire raw material piece containing all segments simultaneously, rather than processing each segment separately in discrete steps. This continuous operation achieves functional region optimization while dramatically reducing production time and improving overall productivity
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 approach simplifies the production process, improves material quality, and reduces handling complexity, enabling more efficient manufacturing of steering gear racks with optimized material properties.
Implementation Method 1
continuous hardening of a raw material piece across a multiple of the segment length in order for a hardened semi-finished segment product to be produced
Data Source
AI summary
A rack for a steering gear of a motor vehicle may include a toothed portion having a toothing, and a shaft portion. Separate segments comprising at least one in each case bar-shaped toothed segment and one shaft segment are provided, are aligned on a common longitudinal axis, and are connected to one another at a joint. The method may involve providing a raw material piece having a piece length that is a multiple of a segment length, thermally continuously hardening the raw material piece across a multiple of a segment length to produce a hardened semi-finished segment product, cutting to length a hardened segment from the hardened semi-finished segment product, providing a further segment, and joining the hardened segment to a further segment.