Steering device and manufacturing method of the same

Abstract

To provide a steering device which makes variations in dimensional accuracy between each of brackets and an outer column less likely to occur, and to provide a manufacturing method of the steering device.SOLUTION: A manufacturing method of a steering device includes: an insertion step in which an inner column is inserted into an outer column; an arrangement step in which a bridge plate is arranged at a Z1 side relative to the outer column while a first support bracket is arranged at a Y1 side relative to the outer column, and a second support bracket is arranged at a Y2 side relative to the outer column; a butted step in which a first joined part in the first support bracket and a second joined part in the bridge plate are butted to form a first butted part and a third joined part in the second support bracket and a fourth joined part in the bridge plate are butted to form a second butted part; and a laser welding step in which laser welding is performed to the first butted part and the second butted part.SELECTED DRAWING: Figure 14

Description

Technical Field

[0001] The present disclosure relates to a steering device and a method for manufacturing the steering device.

Background Art

[0002] In the steering device of Patent Document 1, an outer column and a bracket are joined by laser welding. Specifically, the bracket is abutted against the outer column, and the edge of the bracket is welded to the side portion of the outer column by irradiating laser light along the edge of the bracket.

[0003] In Patent Document 1, since a plurality of brackets are provided, each of the plurality of brackets is joined to the outer column by laser welding. That is, the first bracket is positioned with respect to the outer column, and the first bracket is welded to the outer column. Next, the second bracket is positioned with respect to the outer column, and the second bracket is welded to the outer column. The positioning and welding are similarly performed for the third and subsequent brackets.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Thus, in the welding method of Patent Document 1, since a plurality of brackets are positioned and welded one by one, there is a possibility that variations in dimensional accuracy may occur between each of the plurality of brackets and the outer column. That is, for example, variations are likely to occur in the positional accuracy of the first bracket with respect to the outer column, the positional accuracy of the second bracket with respect to the outer column, and the like.

[0006] The present disclosure has been made in view of the above problems, and an object thereof is to provide a steering device and a method for manufacturing the steering device in which variations in dimensional accuracy between each of a plurality of brackets and an outer column are unlikely to occur.

Means for Solving the Problems

[0007] In order to achieve the above object, a method for manufacturing a steering device according to the present disclosure includes an inner column extending in a first direction, an outer column having the inner column inserted into its inner circumference and being relatively movable with respect to the inner column in the first direction, and a support member of a plate-like member that is attached to a vehicle body and supports the outer column in a state where it can move in a second direction intersecting the first direction. The support member includes a bridge plate located on one side of the outer column in the second direction and extending in a third direction intersecting the first direction and the second direction, a first support bracket located on one side of the outer column in the third direction and extending in the second direction, and a second support bracket located on the other side of the outer column in the third direction and extending in the second direction. A first joint portion provided on the first support bracket and a second joint portion provided on the bridge plate are welded and joined, and a third joint portion provided on the second support bracket and a fourth joint portion provided on the bridge plate are welded and joined. A method for manufacturing a steering device includes an insertion step of inserting the inner column into the outer column, an arrangement step of arranging the bridge plate on one side of the outer column in the second direction, arranging the first support bracket on one side of the outer column in the third direction, and arranging the second support bracket on the other side of the outer column in the third direction, a butting step of moving the first support bracket to the other side of the third direction, moving the second support bracket to one side of the third direction, pressing them against a side surface portion provided on a side portion of the outer column, and then moving the first support bracket to one side of the second direction to butt the first joint portion in the first support bracket and the second joint portion in the bridge plate to form a first butted portion, and moving the second support bracket to one side of the second direction to butt the third joint portion in the second support bracket and the fourth joint portion in the bridge plate to form a second butted portion, and a laser welding step of performing laser welding on each of the first butted portion and the second butted portion.

[0008] As described above, in the welding method of Patent Document 1, the first bracket is positioned with respect to the outer column, and the first bracket is welded to the outer column. Next, the second bracket is positioned with respect to the outer column, and the second bracket is welded to the outer column. The same positioning and welding are performed for the third and subsequent brackets. In this way, since the plurality of brackets are positioned and welded one by one, there is a possibility that variations may occur in the dimensional accuracy between each of the plurality of brackets and the outer column.

[0009] On the other hand, according to the present disclosure, the plurality of brackets are positioned in one step, a butted portion where the joined portions are butted against each other is formed in another step, and laser welding is performed on each butted portion in yet another step. Therefore, an advantage is obtained in that variations are less likely to occur in the dimensional accuracy between each of the plurality of brackets and the outer column. It should be noted that the first joined portion in the first support bracket and the second joined portion in the bridge plate can also be integrally formed.

[0010] Moreover, a method for manufacturing a steering device according to the present disclosure includes an inner column extending in a first direction, an outer column having the inner column inserted into its inner circumference and being relatively movable with respect to the inner column in the first direction, and a support member of a plate-like member that is attached to a vehicle body and supports the outer column in a state movable in a second direction intersecting the first direction. The support member includes a bridge plate located on one side of the outer column in the second direction and extending in a third direction intersecting the first direction and the second direction, a first support bracket located on one side of the outer column in the third direction and extending in the second direction, and a second support bracket located on the other side of the outer column in the third direction and extending in the second direction. A first joint portion provided on the first support bracket and a second joint portion provided on the bridge plate are welded and joined, and a third joint portion provided on the second support bracket and a fourth joint portion provided on the bridge plate are welded and joined. A method for manufacturing a steering device, including: an insertion step of inserting the inner column into the outer column; a sub-assembly preparation step of preparing a sub-assembly in which the third joint portion in the second support bracket and the fourth joint portion in the bridge plate are joined by fillet welding; a first arrangement step of arranging the sub-assembly in a state where the bridge plate is located on one side of the outer column in the second direction and the second support bracket is located on the other side of the outer column in the third direction; a second arrangement step of arranging the first support bracket on one side of the outer column in the third direction; a butting step of moving the second support bracket to one side in the second direction and pressing it against a fixing jig, moving the first support bracket to the other side in the third direction, pressing the second support bracket against a side surface portion provided on a side portion of the outer column, and then moving the first support bracket to one side in the second direction to butt the first joint portion in the first support bracket and the second joint portion in the bridge plate to form a butted portion; and a laser welding step of performing laser welding on the butted portion.

[0011] According to the present disclosure as well, as described above, there is an advantage that variation in dimensional accuracy between each of the plurality of brackets and the outer column is less likely to occur. Further, in the present disclosure, a sub-assembly is formed by the second support bracket and the bridge plate, and the first support bracket is welded to the sub-assembly. Since the sub-assembly is one in which the second support bracket and the bridge plate are pre-joined, the work of positioning the second support bracket with respect to the bridge plate and the work of welding the second support bracket to the bridge plate can be omitted.

[0012] Furthermore, the steering device according to the present disclosure includes an inner column extending in a first direction, an outer column having the inner column inserted into an inner periphery thereof and being relatively movable in the first direction with respect to the inner column, and a support member of a plate-like member attached to a vehicle body and supporting the outer column in a state movable in a second direction intersecting the first direction. The support member includes a bridge plate located on one side in the second direction with respect to the outer column and extending in a third direction intersecting the first direction and the second direction, a first support bracket located on one side in the third direction with respect to the outer column and extending in the second direction, and a second support bracket located on the other side in the third direction with respect to the outer column and extending in the second direction. The first support bracket is joined to the bridge plate via a welded portion by laser welding, and the second support bracket is joined to the bridge plate via a welded portion by fillet welding.

[0013] In the support member, the bridge plate and the first support bracket are joined by laser welding, and the bridge plate and the second support bracket are joined by fillet welding. Comparing fillet welding and laser welding, fillet welding is less costly than laser welding. Therefore, the present disclosure has a lower cost than a mode in which both the first support bracket and the second support bracket are welded to the bridge plate by fillet welding.

[0014] In addition, laser welding has the advantage of being faster than fillet welding in terms of working speed. Therefore, for example, a sub-assembly in which the second support bracket and the bridge plate are joined using slow fillet welding is prepared in advance, and the bridge plate and the first support bracket in the sub-assembly are joined by laser welding, thereby shortening the time required for the joining operation of the support members. Note that the steering apparatus according to the present disclosure is applicable to an electric power steering apparatus, a steer-by-wire apparatus, and the like.

Advantages of the Invention

[0015] According to the present disclosure, it is possible to provide a steering apparatus and a method for manufacturing a steering apparatus in which variations in dimensional accuracy between each of a plurality of brackets and an outer column are less likely to occur.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13A

Figure 13B

Figure 13C

Figure 14

Figure 15

Figure 16A

Figure 16B

Figure 17

Figure 18

Figure 19

Embodiments for Carrying Out the Invention

[0017] Hereinafter, the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited by the following embodiments (hereinafter referred to as embodiments) for carrying out the invention. In addition, the constituent elements in the following embodiments include those that can be easily assumed by those skilled in the art, substantially identical ones, and those within the so-called equivalent range. Furthermore, the constituent elements disclosed in the following embodiments can be combined as appropriate. In the following description, the X direction is also referred to as the first direction or the vehicle longitudinal direction. The X1 side is also referred to as one side in the first direction or the front side FR of the vehicle, and the X2 side is also referred to as the other side in the first direction or the rear side RR of the vehicle. The Y direction is also referred to as the third direction or the vehicle width direction. The Y1 side is also referred to as one side in the third direction or the left side LH of the vehicle, and the Y2 side is also referred to as the other side in the third direction or the right side RH of the vehicle. The Z direction is also referred to as the second direction or the vehicle vertical direction. The Z1 side is also referred to as one side in the second direction or the upper side UPR of the vehicle, and the Z2 side is also referred to as the other side in the second direction or the lower side LWR of the vehicle. Note that all the drawings related to the steering device show a state where the vertical direction is reversed in the vehicle-mounted state.

[0018] [First Embodiment] First, the first embodiment will be described. FIG. 1 is a perspective view of the steering device in the first embodiment. FIG. 2 is an exploded perspective view of the steering device of FIG. 1. FIG. 3 is a view of the steering device of FIG. 1 as seen from the lower side of the vehicle. FIG. 4 is a view of the steering device of FIG. 1 as seen from the upper side of the vehicle. FIG. 5 is a side view of the steering device of FIG. 1 as seen from the side of the vehicle. FIG. 6 is a view of the steering device of FIG. 1 as seen from the rear side of the vehicle. FIG. 7 is a view of the steering device of FIG. 1 as seen from the front side of the vehicle.

[0019] First, the basic configuration of the steering device 1 will be described. As shown in FIGS. 1 and 2, the steering device 1 includes a steering wheel 2, a steering column 4, an upper bracket (support member) 5, and a lower bracket 6. Note that the upper bracket 5 is also referred to as a support member.

[0020] The steering wheel 2 shown in FIG. 1 is connected to a steering shaft (not shown), and the steering shaft is inserted into the inner circumference of the steering column 4 and the front end portion thereof is rotatably fitted to the bearing 120. As shown in FIGS. 1 to 7, the steering column 4 includes an inner column 41 and an outer column 42. The steering column 4 has a central axis AX. The central axis AX extends in the X direction (first direction). That is, the X direction (first direction) coincides with the axial direction of the central axis AX.

[0021] As shown in FIGS. 1 to 7, the inner column 41 has a cylindrical shape. Note that the inner column 41 is not limited to a cylindrical shape, and for example, a polygon such as a hexagon is also applicable. A rotation stopper bracket 410 is fixed to the Z2 side of the outer peripheral surface of the inner column 41. Therefore, the rotation stopper bracket 410 also extends in the X direction. The rotation stopper bracket 410 includes a main body portion 410a, a bent portion 410b, and a bent portion 410c. The main body portion 410a extends in the X direction and is fixed to the outer peripheral surface of the inner column 41. The surface on the Z1 side (the surface facing the inner column 41) of the main body portion 410a may have the same curvature as the inner column 41 to facilitate fixing to the outer peripheral surface of the inner column 41. The bent portion 410b bends from the end portion on the X2 side of the main body portion 410a to the Z2 side. The bent portion 410c bends from the end portion on the X1 side of the main body portion 410a to the Z2 side.

[0022] The outer column 42 includes a first column 42A and a second column 42B. The first column 42A is located on the Y1 side, and the second column 42B is located on the Y2 side. That is, the outer column 42 according to the present embodiment is a pair of columns divided into one side and the other side in the vehicle width direction. In the case of the pair of columns, the first column 42A and the second column 42B can be pushed toward the inner column 41 in the Y direction using a clamp jig, whereby it becomes easy to appropriately set the gap between the first column 42A and the second column 42B and the inner column 41. However, the outer column according to the present invention is not limited to this pair of divided columns. For example, a cylindrical body extending in the circumferential direction around the central axis and having a slit extending in the axial direction is also applicable. The material of the outer column 42 can be widely applied, such as made of aluminum, magnesium, iron, etc. However, in the case of a pair of columns in which the outer column is divided left and right, it is preferable to make it of magnesium because no machining is required after die casting.

[0023] Each of the first column 42A and the second column 42B has a tip portion 422 at the end on the X1 side, and a lower bracket 6 is joined to the tip portion 422. Note that in FIGS. 1 to 7, only the lower bracket 6 joined to the first column 42A is shown.

[0024] As shown in FIG. 2, flanges 421 are respectively formed at the ends on the X2 side in each of the first column 42A and the second column 42B. The flange 421 protrudes in a direction away from the central axis AX in the Y direction. The flange 421 of the first column 42A protrudes to the Y1 side, and the flange 421 of the second column 42B protrudes to the Y2 side. Two flanges 421 are provided separately from each other in the X direction on the first column 42A and the second column 42B. Two side surfaces 421a are provided separately from each other in the Z direction on each of the two flanges 421 separated in the X direction. That is, the flange 421 of the first column 42A has four side surfaces 421a, and the flange 421 of the second column 42B has four side surfaces 421a. A fitting bracket 130 is fitted between the two flanges 421 separated in the X direction. The fitting bracket 130 has a U shape. The end on the Z2 side in the fitting bracket 130 has an end on the Y1 side and an end on the Y2 side. A connecting bar 131 is joined between these ends on the Y1 side and the end on the Y2 side. Pins 132 and 134 are joined to the outer surface in the Y direction of the fitting bracket 130. Specifically, a pin 132 protruding to the Y1 side is joined to the side surface 130a on the Y1 side in the fitting bracket 130, and a pin 134 protruding to the Y2 side is joined to the side surface 130a on the Y2 side in the fitting bracket 130. Further, an inner column 41 is inserted into the inner periphery of the outer column 42, and the inner column 41 slides in the X direction with respect to the outer column 42. That is, the steering device 1 according to the embodiment has a telescopic function.

[0025] The upper bracket 5 and the lower bracket 6 are attached to the vehicle body member (vehicle body) 100 shown in FIGS. 6 and 7. As described above, FIGS. 6 and 7 are also in a state where the up and down are reversed in the vehicle-mounted state.

[0026] The lower bracket 6 is joined to the tip portions 422 of the first column 42A and the second column 42B via a welded portion (laser welded portion) W3 (see FIG. 1) by laser welding. The lower bracket 6 includes a bridge plate 61 and a fixed bracket 62. The bridge plate 61 extends in the Y direction. The fixed brackets 62 are joined to the end portions on the Y1 side and the Y2 side of the bridge plate 61, respectively. Specifically, the fixed bracket 62 has an upper surface 62a located on the Z1 side, and side surfaces 62b, rear surfaces 62c, and front surfaces 62d that rise from the edge of the upper surface 62a toward the Z2 side. The side surface 62b extends in the X direction. The rear surface 62c and the front surface 62d extend in the Y direction. As shown in FIG. 1, the upper surface 62a is joined to the bridge plate 61 via three welded portions W3. Further, the side surface 62b is joined to the pin 63 shown in FIG. 2 via one welded portion W4 (see FIG. 1) by laser welding. Note that the position of the tip portion 422 is the position of a tilt pivot whose tilt position can be adjusted. Furthermore, since the fixed bracket 62 is open in the Y direction and the Z direction, it has the advantage of being easy to irradiate with laser light.

[0027] Next, the upper bracket (support member) 5 will be described. FIG. 8 is a perspective view of the upper bracket of FIG. 1. FIG. 9 is a perspective view of the upper bracket of FIG. 1. FIG. 10 is a perspective view of the bridge plate in FIG. 8. FIG. 11 is a perspective view of the support bracket in FIG. 8. FIG. 12 is a perspective view of the upper bracket of FIG. 1.

[0028] As shown in FIGS. 8 to 12, the upper bracket 5 includes a bridge plate 51 which is a support bracket, a first support bracket 52, and a second support bracket 53. The bridge plate 51 includes a plate body 51a, a vertical wall portion 51b, and a vertical wall portion 51c. The plate body 51a is a rectangular plate member extending in the Y direction. The plate body 51a has two through holes 51d. The two through holes 51d are spaced apart in the Y direction at the maximum separation distance between the first column 42A and the second column 42B in the outer column 42. The vertical wall portion 51b bends and rises from the end on the Y1 side to the Z2 side among the edges on the X1 side of the plate body 51a. The vertical wall portion 51b is located on the Y1 side with respect to the first column 42A (see FIG. 2). The vertical wall portion 51c bends and rises from the end on the Y2 side to the Z2 side among the edges on the X1 side of the plate body 51a. The vertical wall portion 51c is located on the Y2 side with respect to the second column 42B (see FIG. 3).

[0029] As shown in FIGS. 8 and 11, the first support bracket 52 has a base portion 52a and a side wall portion 52b. The base portion 52a extends in the Y direction. The base portion 52a has through holes 52d on the Y1 side and the Y2 side. The side wall portion 52b bends and rises from the end on the Y2 side of the base portion 52a to the Z2 side. The side wall portion 52b has a long hole 52c extending in the Z direction. Note that the inner diameters of the two through holes 51d may be set larger than the inner diameters of the two through holes 52d.

[0030] As shown in FIG. 12, the second support bracket 53 has a base portion 53a and side wall portions 53b. The base portion 53a extends in the Y direction. The base portion 53a has a through hole 53e. The side wall portion 53b bends and rises from the end on the Y1 side of the base portion 53a toward the Z2 side. The side wall portion 53b has a long hole 53c extending in the Z direction. Here, returning to FIG. 2 for explanation, the pin 132 protruding from the side surface 130a on the Y1 side of the fitting bracket 130 is inserted into the long hole 52c of the side wall portion 52b, and the pin 132 is joined to the washer 133 with the tip of the pin 132 inserted into the through hole 133a of the washer 133. Also, a pin 134 protruding from the side surface 130a on the Y2 side of the fitting bracket 130 shown in FIG. 2 is inserted into the long hole 53c of the side wall portion 53b. As a result, the pin 132 moves up and down within the long hole 52c, and the pin 134 moves up and down within the long hole 53c. That is, the steering device 1 according to the embodiment has a tilt function.

[0031] Next, the butting portions of the first support bracket 52 and the bridge plate 51, and the butting portions of the second support bracket 53 and the bridge plate 51 will be described. FIG. 13A is a schematic view of the Q1 portion in FIG. 8 as viewed from the Q2 direction. FIG. 13B is a schematic view of the Q3 portion in FIG. 12 as viewed from the Q4 direction. FIG. 13C is a schematic view of the vicinity of the plate thickness surface of the side wall portions in FIGS. 13A and 13B.

[0032] As shown in FIG. 13A, a first joint portion P1 is provided on the first support bracket 52, a second joint portion P2 is provided on the bridge plate 51, and the first joint portion P1 and the second joint portion P2 are butted against each other to form a first butting portion P10. The following will be described in detail.

[0033] The first joint portion P1 is a plate thickness surface 52e located at the X1-side end of the side wall portion 52b of the first support bracket 52. The plate thickness surface 52e is, for example, a processed surface obtained by cutting a metal plate by press shearing. As shown in FIGS. 13A and 13C, it has a slanting portion 151, a shearing portion 152, a fracture portion 153, and a burr portion 154. Among the processed surfaces of the shearing process, the shearing portion 152 extends parallel to the Y direction. In other words, the shearing portion 152 is shaped into a planar shape that is substantially orthogonal to the front and back surfaces of the side wall portion 52b.

[0034] As shown in FIG. 13A, the second joint portion P2 is a portion provided on the vertical wall portion 51b of the bridge plate 51. The second joint portion P2 is a portion that faces the first joint portion P1 and abuts against the first joint portion P1. The first joint portion P1 and the second joint portion P2 are abutted against each other to form a first abutting portion P10.

[0035] Also, as shown in FIG. 13B, a third joint portion P3 is provided on the second support bracket 53, and a fourth joint portion P4 is provided on the bridge plate 51. The third joint portion P3 and the fourth joint portion P4 are abutted against each other to form a second abutting portion P20. This will be described in detail below.

[0036] The third joint portion P3 is a plate thickness surface 53d located at the X1-side end of the side wall portion 53b of the second support bracket 53. The plate thickness surface 53d is, for example, a processed surface obtained by cutting a metal plate by press shearing. As shown in FIGS. 13B and 13C, it has a slanting portion 151, a shearing portion 152, a fracture portion 153, and a burr portion 154.

[0037] As shown in FIG. 13B, the fourth joint portion P4 is a portion provided on the vertical wall portion 51c of the bridge plate 51. The fourth joint portion P4 is a portion that faces the third joint portion P3 and abuts against the third joint portion P3. The third joint portion P3 and the fourth joint portion P4 are abutted against each other to form a second abutting portion P20.

[0038] Next, the welded part will be briefly described. As shown in Fig. 8, the first support bracket 52 and the bridge plate 51 are joined by three laser welded parts W1. Specifically, the side wall part 52b and the vertical wall part 51b are joined via the welded part W11 by laser welding. The base part 52a and the plate body 51a are joined via the welded parts W12 and W13 by laser welding. The welded part W12 is located at the end on the Y2 side of the base part 52a with the through hole 52d therebetween, and the welded part W13 is located at the end on the Y1 side of the base part 52a with the through hole 52d therebetween.

[0039] As shown in Fig. 12, the second support bracket 53 and the bridge plate 51 are joined by three laser welded parts W1. Specifically, the side wall part 53b and the vertical wall part 51c are joined via the welded part W14 by laser welding. The base part 53a and the plate body 51a are joined via the welded parts W15 and W16 by laser welding. The welded part W16 is located at the end on the Y2 side of the base part 52a with the through hole 53e therebetween, and the welded part W15 is located at the end on the Y1 side of the base part 52a with the through hole 53e therebetween.

[0040] Next, the manufacturing method of the steering device will be described. Specifically, the procedure for welding and joining the first support bracket 52 and the second support bracket 53 to the bridge plate 51 will be described. Fig. 14 is a schematic diagram showing a state in which the Q3 part in Fig. 12 is being laser welded. Fig. 15 is a perspective view showing the order of positioning operations when assembling the steering device in Fig. 1 by welding. Fig. 16A is a schematic diagram showing a state in which a shim is inserted between the outer column and the inner column. Fig. 16B is a schematic diagram showing a state in which the shim is removed from the state of Fig. 16A.

[0041] The manufacturing method of the steering device includes an insertion step, an arrangement step, a butting step, and a laser welding step.

[0042] As shown in FIG. 15, in the insertion step, the inner column 41 is inserted into the inner circumference of the outer column 42. Specifically, the inner column 41 is sandwiched between the first column 42A and the second column 42B.

[0043] In the arrangement step, the upper brackets 5 are arranged on both the upper side of the vehicle and both sides in the vehicle width direction of the inner column 41. Specifically, as shown in FIG. 2, a bridge plate 51 is arranged on the Z1 side with respect to the inner column 41, a first support bracket 52 is arranged on the Y1 side with respect to the inner column 41, and a second support bracket 53 is arranged on the Y2 side with respect to the inner column 41.

[0044] In the butting step, first, as shown in FIG. 16A, a shim (thin plate) 110 is sandwiched between the side surface portion 421a of the flange 421 in the first column 42A and the side wall portion 52b of the first support bracket 52. Then, as shown in FIG. 15, each of the first support bracket 52 and the second support bracket 53 is moved in the Y direction toward the inner column 41 and pressed against the side surface portion 421a (see FIG. 2) provided on the side portion of the inner column 41. Specifically, as shown in FIG. 15, the side wall portion 52b is moved in the S1 direction and pressed against the shim 110, and the side wall portion 53b is moved in the S2 direction and pressed against the side surface portion 421a (see FIG. 2). After that, the first support bracket 52 is moved in the S3 direction so that the base portion 52a of the first support bracket 52 is pressed against the plate body 51a of the bridge plate 51 and the first support bracket 52 is pushed in the X1 direction. Thereby, as described above with reference to FIG. 13A, the first joint portion P1 and the second joint portion P2 can be butted to form the first butted portion P10. Also, as shown in FIG. 15, the second support bracket 53 is moved in the S4 direction so that the base portion 53a (see FIG. 12) of the second support bracket 53 is pressed against the plate body 51a of the bridge plate 51 and the second support bracket 53 is pushed in the X1 direction. Thereby, as described above with reference to FIG. 13B, the third joint portion P3 and the fourth joint portion P4 can be butted to form the second butted portion P20.

[0045] In the laser welding step, as shown in FIG. 14, the laser welding machine 140 is disposed on the Y1 side or the Y2 side with respect to the side wall portion 53b. Then, laser light 141 is irradiated from the laser welding machine 140 on the Y1 side or the Y2 side with respect to the side wall portion 53b to perform laser welding.

[0046] Here, among the first butting portions P10 (see FIG. 13B), the region irradiated with the laser light 141 is most preferably the region R1 shown in FIG. 14. The region R1 is a region where the shearing surface portion 152 in the side wall portion 53b and the vertical wall portion 51c are butted against each other. Since the shearing surface portion 152 is a plane substantially orthogonal to the front and back surfaces of the side wall portion 53b as described above, the intersection angle between the shearing surface portion 152 and the vertical wall portion 51c is likely to be a right angle, and a gap is less likely to occur between the shearing surface portion 152 and the vertical wall portion 51c. Note that the region R2 shown in FIG. 14 is a region where the fracture surface portion 153 in the side wall portion 53b and the vertical wall portion 51c are butted against each other, and the laser light 141 may be irradiated toward the region R2.

[0047] As shown in FIGS. 16A and 16B, the thickness C of the shim 110 is the sum of (2 × gap A) and (2 × gap B). The gap A is a gap between the inner column 41 and the first column 42A along the Y direction passing through the central axis AX. Also, the gap A is a gap between the inner column 41 and the second column 42B along the Y direction passing through the central axis AX. The gap B is a gap between the side surface portion 421a of the outer column 42 and the side wall portion 52b, or a gap between the side surface portion 421a of the outer column 42 and the side wall portion 53b. That is, the thickness C of the shim 110 is substantially the same as the total of the gaps along the Y direction passing through the central axis AX between the inner column 41, the first column 42A, and the second column 42B. Here, the gap A between the inner column 41 and the outer column 42 is a gap for the telescopic function in which the inner column 41 slides in the X direction with respect to the outer column 42. Also, the gap B between the outer column 42 and the side wall portion 53b is a gap for the tilt function in which the outer column 42 moves up and down with respect to the vehicle body. Note that the shim 110 is removed after the laser welding is completed.

[0048] As described above, the manufacturing method of the steering apparatus 1 according to the first embodiment includes an insertion step of inserting the inner column 41 into the outer column 42, an arrangement step of arranging the bridge plate 51 on the Z1 side with respect to the outer column 42, arranging the first support bracket 52 on the Y1 side with respect to the outer column 42, and arranging the second support bracket 53 on the Y2 side with respect to the outer column 42, a butting step of butting the first joint portion P1 in the first support bracket 52 and the second joint portion P2 in the bridge plate 51 to form the first butted portion P10, and butting the third joint portion P3 in the second support bracket 53 and the fourth joint portion P4 in the bridge plate 51 to form the second butted portion P20, and a laser welding step of performing laser welding on each of the first butted portion P10 and the second butted portion P20.

[0049] As described above, in the welding method of Patent Document 1, the first bracket is positioned with respect to the outer column 42, and the first bracket is welded to the outer column 42. Next, the second bracket is positioned with respect to the outer column 42, and the second bracket is welded to the outer column 42. The same positioning and welding are performed for the third and subsequent brackets. Thus, since the plurality of brackets are positioned and welded one by one, there is a possibility that variations may occur in the dimensional accuracy between each of the plurality of brackets and the outer column 42.

[0050] On the other hand, according to the present embodiment, since the positioning of the plurality of brackets is performed in one step, the butted portions where the joint portions are butted against each other are formed in another step, and laser welding is performed on the butted portions in still another step, there is an advantage that variations are less likely to occur in the relative dimensional accuracy between the plurality of brackets and the outer column 42.

[0051] [Second Embodiment] Next, the second embodiment will be described. FIG. 17 is a perspective view of the upper bracket in the second embodiment.

[0052] In the first embodiment, three components, namely, the bridge plate 51, the first support bracket 52, and the second support bracket 53, were joined by laser welding. In the second embodiment, a sub-assembly 5B in which the second support bracket 53 and the bridge plate 51 are integrated is used. Note that the term "integration" includes, for example, integration by welding and integration by press-forming a single metal plate. This will be described in detail below.

[0053] As shown in FIG. 17, the upper bracket (support member) 5A according to the second embodiment includes a sub-assembly 5B and a first support bracket 52. The sub-assembly 5B is formed by joining the second support bracket 53 and the bridge plate 51 by fillet welding and spot welding. Specifically, a third joint portion P3 (see FIG. 13B) in the second support bracket 53 and a fourth joint portion P4 (see FIG. 13B) in the bridge plate 51 are joined via a weld portion W21 by fillet welding. Further, the base portion 53a and the plate body 51a are joined via weld portions W22, W23 by spot welding. Note that the sub-assembly 5B may be formed by joining the first support bracket 52 and the bridge plate 51 by fillet welding and spot welding. Note that fillet welding includes, for example, covered arc welding, MAG welding, TIG welding, and the like. Further, the base portion 53a and the plate body 51a can also be joined by fillet welding.

[0054] Next, a method for manufacturing the steering device will be described. Specifically, a procedure for welding and joining the first support bracket 52 to the sub-assembly 5B will be described. FIG. 18 is a perspective view showing the order of positioning operations when assembling the steering device of FIG. 17 by welding.

[0055] The method for manufacturing the steering device includes an insertion step, a sub-assembly preparation step, a first placement step, a second placement step, a butting step, and a laser welding step.

[0056] As shown in Fig. 18, in the insertion step, the inner column 41 is inserted into the inner circumference of the outer column 42. Specifically, the inner column 41 is sandwiched between the first column 42A and the second column 42B.

[0057] In the sub-assembly preparation step, the above-described sub-assembly 5B is prepared.

[0058] In the first placement step, the sub-assembly 5B is placed near the outer column 42. Specifically, the sub-assembly 5B is placed such that the bridge plate 51 is positioned on the Z1 side with respect to the outer column 42 and the second support bracket 53 is positioned on the Y2 side with respect to the outer column 42.

[0059] In the second placement step, the first support bracket 52 is placed on the Y1 side with respect to the outer column 42.

[0060] In the butting step, first, the second support bracket 53 is moved in the S11 direction shown in Fig. 18 and pressed against a fixing jig (not shown) to position the second support bracket 53. Next, the first support bracket 52 is moved in the S12 direction on the Y2 side, and after pressing the second support bracket 53 against the side surface portion 421a provided on the side portion of the outer column 42, the first support bracket 52 is moved in the S13 direction on the Z1 side and the X1 side to butt the first joint portion P1 (see Fig. 13A) in the first support bracket 52 and the second joint portion P2 (see Fig. 13A) in the bridge plate 51 to form a butted portion (the first butted portion P10 shown in Fig. 13A).

[0061] In the laser welding step, as described with reference to Fig. 14, laser welding is performed on the butted portion.

[0062] As described above, the manufacturing method of the steering apparatus 1A according to the second embodiment includes an insertion step of inserting the inner column 41 into the outer column 42, a sub-assembly preparation step of preparing a sub-assembly 5B in which a third joint portion P3 in the second support bracket 53 and a fourth joint portion P4 in the bridge plate 51 are joined by fillet welding, a first arrangement step of arranging the sub-assembly 5B in a state where the bridge plate 51 is positioned on the Z1 side with respect to the outer column 42 and the second support bracket 53 is positioned on the Y2 side with respect to the outer column 42, a second arrangement step of arranging the first support bracket 52 on the Y1 side with respect to the outer column 42, a butting step of butting a first joint portion P1 in the first support bracket 52 and a second joint portion P2 in the bridge plate 51 to form a butted portion, and a laser welding step of performing laser welding on the butted portion.

[0063] In the present disclosure, the sub-assembly 5B is formed by the second support bracket 53 and the bridge plate 51, and the first support bracket 52 is welded to the sub-assembly 5B. Since the second support bracket 53 and the bridge plate 51 are pre-joined in the sub-assembly 5B, the work of positioning the second support bracket 53 with respect to the bridge plate 51 and the work of welding the second support bracket 53 to the bridge plate 51 can be omitted.

[0064] Also, in the steering apparatus 1A, the upper bracket (support member) 5A includes a bridge plate 51 positioned on the Z1 side with respect to the outer column 42, a first support bracket 52 positioned on the Y1 side with respect to the outer column 42, and a second support bracket 53 positioned on the Y2 side with respect to the outer column 42. The first support bracket 52 is joined to the bridge plate 51 via a welded portion W1 by laser welding, and the second support bracket 53 is joined to the bridge plate 51 via a welded portion W21 by fillet welding.

[0065] In the upper bracket 5, the bridge plate 51 and the first support bracket 52 are joined by laser welding, and the bridge plate 51 and the second support bracket 53 are joined by fillet welding. Comparing fillet welding with laser welding, the cost of fillet welding is lower. Therefore, the present disclosure results in a lower cost than the mode of welding both the first support bracket 52 and the second support bracket 53 to the bridge plate 51 by laser welding.

[0066] Also, laser welding has the advantage of being faster in working speed than fillet welding. Therefore, for example, the sub-assembly 5B is pre-formed and prepared in advance with the second support bracket 53 and the bridge plate 51 using slow fillet welding. In the welding process, if the bridge plate 51 and the first support bracket 52 in the sub-assembly 5B are joined by laser welding, the welding time of the support member can be shortened.

[0067] In addition, in the first and second embodiments, as shown in FIGS. 15 and 18, the step of butting and welding the fixed bracket 62 against the bridge plate 61 is also included. For example, in the first embodiment, in the butting step, as shown in FIG. 15, the fixed bracket 62 attached to the tip 422 of the first column 42A is moved in the S5 direction to press the upper surface 62a against the bridge plate 61, and then the tip 422 is moved in the S6 direction to press it against the side surface 62b of the fixed bracket 62. Also, in the second embodiment, for the fixed bracket (not shown) attached to the tip 422 of the second column 42B, after moving the fixed bracket in the S7 direction to press it against the tip 422, the fixed bracket is moved in the S8 direction to press it against the bridge plate 61.

[0068] Furthermore, in the embodiment, the mode with the outer column on the lower side has been described, but the mode with the outer column on the upper side may also be used.

[0069] The materials of the bridge plates 51 and 61 may be iron or aluminum. In particular, the non-sliding parts may be made of aluminum to reduce the weight.

[0070] [Modification Example] Next, the modification example will be described. FIG. 19 is a schematic diagram of a steering device according to the modification example and shows the attitude of mounting on a vehicle. In FIG. 19, the intermediate shaft, the rack and pinion, the vehicle body, etc. are omitted.

[0071] As shown in FIG. 19, the steering device 1 may be attached to the vehicle body in a forward and obliquely downward direction. In other words, the central axis AX (see FIGS. 1 and 18) of the steering column 4 may be inclined with respect to the vehicle body. That is, the steering device 1 may be arranged in an oblique attitude with respect to the vehicle body so as to go downward with respect to the vehicle body as it goes forward in the vehicle body. Note that when the steering device 1 is attached to the vehicle body in a forward and obliquely downward direction as in the modification example, the vertical direction of the vehicle body and the vertical direction of the steering device itself do not necessarily coincide.

Explanation of Reference Numerals

[0072] 1, 1A Steering device 2 Steering wheel 4 Steering column 41 Inner column 410 Rotation stop bracket 410a Body part 410b Bending part 410c Bending part 42 Outer column 42A First column 42B Second column 421 Flange 421a Side surface part 422 Tip part 5 Upper bracket (support member) 5A Upper bracket (support member) 5B Sub-assembly 51 Bridge plate 51a Plate body 51b Vertical wall portion 51c Vertical wall portion 51d Through hole 52 First support bracket 52a Base portion 52b Side wall portion 52c Long hole 52d Through hole 52e Plate thickness surface 53 Second support bracket 53a Base portion 53b Side wall portion 53c Long hole 53d Plate thickness surface 53e Through hole 6 Lower bracket 61 Bridge plate 62 Fixed bracket 62a Upper surface 62b Side surface 62c Rear surface 62d Front surface 100 Vehicle body member (vehicle body) 110 Shim 120 Bearing 130 Fitting bracket 130a Side surface 131 Connecting bar 132 Pin 133 Washer 140 Laser welding machine 141 Laser beam 151 Slack portion 152 Shear surface portion 153 Fracture surface portion 154 Burr portion A Gap B Gap C Thickness P1 First joint portion P2 Second joint portion P3 Third joint portion P4 Fourth joint portion P10 First butting portion P20 Second butting portion W1 Weld portion (laser weld portion) W11 Weld portion W12 Welding part W13 Welding part W14 Welding part W15 Welding part W16 Welding part W21 Welding part (fillet welding part) W22 Welding part (spot welding part) W23 Welding part (spot welding part)

Claims

1. An inner column extending in a first direction, an outer column into which the inner column is inserted on its inner periphery, and a support member of a plate-like member that is attached to a vehicle body and supports the outer column in a state movable in a second direction intersecting the first direction, wherein the support member includes a bridge plate located on one side of the outer column in the second direction and extending in a third direction intersecting the first direction and the second direction, a first support bracket located on one side of the outer column in the third direction and extending in the second direction, and a second support bracket located on the other side of the outer column in the third direction and extending in the second direction, a manufacturing method of a steering device, wherein a first joint portion provided on the first support bracket and a second joint portion provided on the bridge plate are welded and joined, and a third joint portion provided on the second support bracket and a fourth joint portion provided on the bridge plate are welded and joined, comprising: an insertion step of inserting the inner column into the outer column; an arrangement step of arranging the bridge plate on one side of the outer column in the second direction, arranging the first support bracket on one side of the outer column in the third direction, and arranging the second support bracket on the other side of the outer column in the third direction; a butting step of moving the first support bracket to the other side in the third direction, moving the second support bracket to one side in the third direction, pressing them against side faces provided on side portions of the outer column, then moving the first support bracket to one side in the second direction to butt the first joint portion in the first support bracket and the second joint portion in the bridge plate to form a first butted portion, and moving the second support bracket to one side in the second direction to butt the third joint portion in the second support bracket and the fourth joint portion in the bridge plate to form a second butted portion; a laser welding step of performing laser welding on each of the first butted portion and the second butted portion. A manufacturing method of a steering device.

2. An inner column extending in a first direction, an outer column into which the inner column is inserted on its inner periphery, and a support member of a plate-like member that is attached to a vehicle body and supports the outer column in a state movable in a second direction intersecting the first direction, wherein the support member includes a bridge plate located on one side in the second direction with respect to the outer column and extending in a third direction intersecting the first direction and the second direction, a first support bracket located on one side in the third direction with respect to the outer column and extending in the second direction, and a second support bracket located on the other side in the third direction with respect to the outer column and extending in the second direction, and a manufacturing method of a steering device in which a first joint portion provided on the first support bracket and a second joint portion provided on the bridge plate are welded and joined, and a third joint portion provided on the second support bracket and a fourth joint portion provided on the bridge plate are welded and joined, An insertion step of inserting the inner column into the outer column, A sub-assembly preparation step of preparing a sub-assembly in which the third joint portion in the second support bracket and the fourth joint portion in the bridge plate are joined by fillet welding, A first arrangement step of arranging the sub-assembly in a state where the bridge plate is located on one side in the second direction with respect to the outer column and the second support bracket is located on the other side in the third direction with respect to the outer column, A second arrangement step of arranging the first support bracket on one side in the third direction with respect to the outer column, A butting step of moving the second support bracket to one side in the second direction and pressing it against a fixing jig, moving the first support bracket to the other side in the third direction, pressing the second support bracket against a side surface portion provided on a side portion of the outer column, and then moving the first support bracket to one side in the second direction to butt the first joint portion in the first support bracket and the second joint portion in the bridge plate to form a butted portion, A laser welding step of performing laser welding on the butted portion, A manufacturing method of a steering device.

3. An inner column extending in a first direction, An outer column into which the inner column is inserted on the inner periphery, a support member of a plate-like member that is attached to the vehicle body and supports the outer column in a state movable in a second direction intersecting the first direction, comprising: the support member is a bridge plate located on one side in the second direction with respect to the outer column and extending in a third direction intersecting the first direction and the second direction, a first support bracket located on one side in the third direction with respect to the outer column and extending in the second direction, a second support bracket located on the other side in the third direction with respect to the outer column and extending in the second direction, having: the first support bracket is joined to the bridge plate via a welded portion by laser welding, the second support bracket is joined to the bridge plate via a welded portion by fillet welding, a steering device.

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