Wheel Bearing Mount Flange Attenuating Impact Forces
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Solution Overview
Problem
Wheel bearing assemblies in modern vehicles are susceptible to damage from side impact forces, leading to undesirable noise and vibration due to stress exceeding the elastic limit of raceway materials, as larger wheels and more rigid suspension components increase the risk of 'Brinelling', and previous solutions that increase the size of rolling elements result in inefficiencies and higher costs.
Innovation Solution
A support member for wheel bearing assemblies featuring a central sleeve with a mounting flange that tapers into equally spaced lobes, providing a reduced contact area with the vehicle and allowing the flange to flex and absorb side impact loads, thereby dampening the forces transmitted to the bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the size of rolling elements is increased to prevent Brinelling, then the resistance to impact forces is improved, but the mass and weight of the bearing components increase
Solution Approach 1:
The mounting flange acts as an intermediary element between the bearing assembly and the vehicle suspension. It includes a flexible element positioned between the flange and the vehicle that absorbs and attenuates impact forces before they reach the bearing rolling elements, thereby protecting the bearings without requiring larger rolling elements
Solution Approach 2:
The flexible element in the mounting flange provides beforehand cushioning by being pre-positioned to absorb impact forces from curbs or other objects before these forces can be transmitted to the bearing rolling elements, preventing Brinelling without increasing bearing size
2Strength
If the size of rolling elements is increased to prevent Brinelling, then the resistance to impact forces is improved, but the cost of the bearing components increases
Solution Approach 1:
The mounting flange with flexible element serves as a cost-effective intermediary solution that protects bearings from impact forces without requiring expensive larger rolling elements, thereby reducing the overall cost while maintaining protection against Brinelling
Solution Approach 2:
The flexible element provides beforehand cushioning at a lower cost than increasing bearing component size, absorbing impact forces before they reach the bearings and preventing Brinelling through a more economical approach
3Strength
If the size of rolling elements is increased to prevent Brinelling, then the resistance to impact forces is improved, but the vehicle straight-running and cornering capabilities are degraded
Solution Approach 1:
The mounting flange with flexible element acts as a mediator that protects bearings from impact forces without affecting the bearing's rotational performance, thereby maintaining vehicle straight-running and cornering capabilities while preventing Brinelling
Solution Approach 2:
The flexible element provides beforehand cushioning that protects the bearings without interfering with their rotational function, preserving vehicle handling characteristics while preventing impact-related damage
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 effectively reduces and localizes impact forces on the bearing members, minimizing the risk of 'Brinelling' and associated noise and vibration while maintaining efficient vehicle performance by distributing and absorbing side impact loads through the flexible flange design.
Implementation Method 1
the central portion of the flange may be configured to act as a spring member. This enables the flange central portion to flex in response to a side impact load experienced by a wheel assembly attached to the vehicle via the wheel bearing assembly. This flexibility enables the flange to absorb a portion of the side impact load, thereby dampening or attenuating the portion of the load transmitted to the bearings.
Data Source
AI summary
A support member (14) for rotatably coupling a first element to a second element. The support member includes a sleeve (50) for rotatably supporting the first element, and a flange (56) having a concave central portion. The flange (56) is coupled to the sleeve (50). The flange (56) has bearing surfaces (68a, 68b) formed thereon along which the flange (56) is mounted to the second element. In one embodiment, the first element is a spindle (12) of a vehicle wheel assembly (11) and is rotatably supported in the sleeve (50) by rollable bearing elements positioned therein. Multiple tapered lobes (64) extend outwardly from the sleeve (50), and the support member (14) is mounted to a vehicle via bearing surfaces (68a, 68b) along the lobes (64). Due to the concave portion of the flange (56), the bearing surfaces (68a, 68b) are the only portions of the flange (56) in contact with the vehicle when the support member (14) is secured to the vehicle, reducing the contact area between the flange (56) and the vehicle, and reducing impact forces transferred to the bearings. A portion of the flange (56) may act as a spring member, enabling the flange (56) to flex in response to an impact load experienced by the wheel bearing assembly (11). This enables the flange (56) to absorb a portion of the side impact load, thereby attenuating the portion of the load transmitted to the bearings. A wheel bearing assembly (10) incorporating the support member (14) is also disclosed.