Wheel Suspension Bearing Mount With Stepped Outer Race Gap
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Solution Overview
Problem
Current wheel suspension designs in vehicles suffer from unwanted deformations and increased wheel bearing friction due to full-surface contact between the wheel bearing and wheel carrier, leading to noise and sensitivity to micro-movements, which are not effectively addressed by existing curvature-based solutions.
Innovation Solution
A wheel suspension design featuring a wheel bearing outer ring with a step or gap in the rotation axis direction, allowing for a form-fitting connection and decoupling of deformations at screw-on points from wheel bearing raceways, reducing friction and micro-movements, and incorporating a forged or cast construction for enhanced stiffness and manufacturing advantages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the wheel bearing is clamped to the wheel carrier with full-surface contact, then the connection stability is improved, but the wheel bearing friction increases and noise is generated due to deformations
Solution Approach 1:
The flange surface is segmented into multiple contact zones separated by gaps, rather than providing full-surface contact. This segmentation allows the connection to remain stable while preventing continuous deformation transmission to the raceways, thereby reducing friction and noise
Solution Approach 2:
Different regions of the flange surface have different properties: contact zones provide stable connection while gap regions prevent deformation transmission. The local quality varies between contact areas (high stability) and gap areas (low friction transmission)
2Stress or pressure
If a curvature is introduced in the flange surface to allow elastic deformation, then the surface pressure is improved, but the raceways are deformed and wheel bearing friction increases
Solution Approach 1:
The flange surface is divided into discrete contact zones separated by gaps, allowing localized elastic deformation in contact areas to achieve sufficient surface pressure while preventing deformation transmission to the raceways through the gap regions
Solution Approach 2:
The harmful continuous contact between flange and wheel bearing outer ring is extracted by introducing gaps, removing the deformation transmission path while maintaining necessary contact pressure in discrete zones
3Stress or pressure
If the flange surface is made non-planar to achieve elastic deformation, then the contact surface pressure is improved, but the manufacturing precision and strength are compromised
Solution Approach 1:
Instead of making the entire flange surface non-planar, only discrete contact zones are shaped to provide elastic deformation, while gap regions maintain simple geometry for high manufacturing precision and structural strength
4Strength
If full-surface contact is used between wheel bearing and wheel carrier, then the connection rigidity is improved, but micro-movements occur leading to noise
Solution Approach 1:
The continuous contact surface is segmented into discrete contact zones separated by gaps, maintaining connection rigidity through adequate contact area while preventing micro-movements by eliminating continuous deformation paths
Data Source
AI summary
A wheel suspension for a vehicle includes a wheel carrier with a flange and a wheel bearing which is fastened to the wheel carrier and has a wheel bearing outer race. The flange of the wheel carrier lies flat against the wheel bearing outer race of the wheel bearing. The wheel bearing is clamped against the wheel carrier by way of a plurality of screws distributed over the circumference of the wheel bearing outer race. A surface of the wheel bearing outer race that faces the flange has at least one step, as viewed in the direction of the rotation axis of the wheel bearing, which step is designed such that, in the screwed state of the wheel bearing outer race to the wheel carrier flange, a gap is formed in the region of the step between the wheel bearing outer race and the wheel carrier flange.