Wheel Module Steering Lever Assembly for Large Steering Angles

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Solution Overview

Problem

Motor vehicles face challenges in achieving a large steering angle within a small installation space, as existing solutions require significant space and are costly due to the use of rotary gear mechanisms.

Innovation Solution

A wheel module with a linear actuator-based steering system, utilizing a main lever and intermediate lever to convert linear movement into pivoting movement, allowing for large steering angles without the need for backlash-free rotary gears, and incorporating an electromechanical steering actuator and wheel hub drive for independent wheel actuation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a rotary steering actuator with backlash-free rotary gear is used, then steering precision is improved, but installation space and cost increase

Engineering Contradiction:

Improvesteering precisionVSAvoidinstallation space

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The patent replaces the rotary steering actuator with a linear steering actuator. The linear actuator converts rotational motion of its output shaft into linear motion through a sector gear and rack mechanism, eliminating the need for complex backlash-free rotary gears while maintaining steering precision and reducing installation space requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The steering system is divided into separate functional components: the linear actuator provides precise positional control, while the sector gear and rack mechanism converts this to rotational steering motion. This segmentation allows each component to be optimized independently, reducing overall space requirements while maintaining precision.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If a linear actuator is used instead of rotary actuator, then installation space is reduced, but steering angle capability must be maintained

Engineering Contradiction:

Improveinstallation spaceVSAvoidsteering angle capability

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

The patent uses a sector gear with a specific arc angle (e.g., 90 degrees) that translates linear motion into rotational motion over a large angular range. This dimensional transformation allows the compact linear actuator to achieve the same steering angle capability as a rotary actuator would provide.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The sector gear-rack mechanism acts as an intermediary between the linear actuator and the wheel steering system. It converts the limited linear displacement of the actuator into a large rotational steering angle, enabling the linear actuator to achieve steering angle capabilities comparable to rotary actuators.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If independent wheel actuation is implemented, then maneuverability is improved, but device complexity increases

Engineering Contradiction:

ImprovemaneuverabilityVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs identical linear actuator mechanisms for each wheel, allowing independent actuation of multiple wheels. Each wheel module is self-contained with its own linear actuator, enabling versatile maneuvers such as parallel parking and tight cornering while using standardized components that reduce overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables vehicles to achieve steering angles of at least 130°, allowing for tight cornering and parking in narrow spaces without additional installation space, while providing flexibility in vehicle direction and a small turning radius, and enabling energy recuperation during braking.

Implementation Method 1

the steering actuator is in the form of a linear actuator; The steering actuator can be designed as an electromechanical actuator. This means that the steering actuator has an electrical machine for delivering an electrically generated steering torque

Methodology Applied

Scientific EffectElectromechanical conversion: Linear Motor

Implementation Method 2

the steering angle acts on the steering arm via a main lever and an intermediate lever, which enables a turning in of the wheel module. This means that the linear movement of the steering actuator is converted into a pivoting movement of the main lever and is transmitted to the steering arm via the intermediate lever

Methodology Applied

Scientific EffectLeverage: Lever

Data Source

PatentUS20230322299A1Wheel module for a motor vehicle

Publication Date: 2023.10.12 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

The disclosure relates to a wheel module of a motor vehicle that includes a wheel and a steering lever assembly for a steering movement to the wheel. The steering lever assembly can be rotatably mounted on a support frame of the motor vehicle. A steering actuator for introducing a steering movement is connected to the steering lever assembly. The steering actuator is in the form of linear actuator. The steering lever assembly has a main lever connected to the steering actuator by means of a first connection region, and a steering lever connected to the main lever by means of an intermediate lever.