Adjustable Bearing Unit for Vehicle Steering Wheel Assembly
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Solution Overview
Problem
In vehicle assemblies, especially in the vehicle interior, achieving uniform and narrow clearances between supports and components is challenging due to manufacturing tolerances, which can lead to jamming and restricted functionality, requiring higher accuracy that is difficult to achieve with conventional methods.
Innovation Solution
A method involving a bearing unit with at least two orientable bearing members, where one member has a contact surface and the other a bearing surface, allowing for precise alignment and fastening through ultrasonic softening and deformation, enabling accurate orientation and positioning despite high manufacturing tolerances, using either form or material closure for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used with standard tolerances, then manufacturing effort is reduced, but clearance uniformity and positioning accuracy deteriorate
Solution Approach 1:
The bearing unit is divided into multiple bearing members (at least two) that can be individually oriented and adjusted. This segmentation allows each bearing member to be positioned independently to compensate for manufacturing tolerances, achieving uniform clearances without requiring high-precision manufacturing of all components.
Solution Approach 2:
The bearing members are designed to be movable and adjustable relative to each other during assembly, allowing dynamic orientation and positioning. This dynamic capability enables adaptation to actual dimensional variations of the support and component, achieving precise clearance control without fixed high-tolerance requirements.
2Manufacturing precision
If high accuracy components are manufactured to achieve required clearances, then clearance uniformity is improved, but manufacturing effort and cost increase substantially
Solution Approach 1:
The invention changes the approach from controlling component dimensions to controlling relative positions. By using adjustable bearing members with degrees of freedom, the system compensates for dimensional variations through position adjustments rather than requiring tight dimensional controls, thereby reducing manufacturing effort.
Solution Approach 2:
The bearing unit itself provides the adjustment mechanism to compensate for manufacturing tolerances. The bearing members can be individually oriented and positioned to self-correct for dimensional variations in the support and component, eliminating the need for high-precision manufacturing while achieving required clearance uniformity.
3Shape
If clearances are made narrow for optical reasons, then aesthetic appearance is improved, but risk of jamming increases
Solution Approach 1:
The bearing members are designed with movable capabilities that allow them to adapt to dimensional variations and maintain reliable clearances. This dynamic adjustment ensures that even with narrow clearances for aesthetic purposes, the component can move freely without jamming by compensating for manufacturing tolerances through bearing member positioning.
4Manufacturing precision
If bearing members are precisely manufactured to size, then positioning accuracy is improved, but adaptability to actual dimensions deteriorates
Solution Approach 1:
The bearing members are designed to be movable and adjustable during assembly, allowing them to adapt to the actual dimensions of the support and component. This dynamic capability enables the bearing unit to compensate for dimensional variations without requiring high-precision pre-manufacturing of individual bearing members.
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 method allows for exact orientation and secure fastening of components, accommodating manufacturing tolerances, ensuring proper alignment and preventing jamming, while allowing for the use of slightly oversized parts, thus simplifying the series production of vehicle assemblies like steering wheel and horn modules.
Implementation Method 1
at least one bearing member is softened by means of an ultrasonic device in the area of the bearing surface
Implementation Method 2
fastening the two bearing members to each other by material closure and/or form closure
Data Source
AI summary
A method for series production of a vehicle assembly, especially an interior assembly, including a vehicle-side support, especially a vehicle steering wheel (12), and a component to be fastened at the support, especially a horn module (14), wherein a module-side bearing unit (22) consisting of at least two bearing members (46, 50) is assigned to the component and/or a support-side bearing unit (24) consisting of at least two bearing members (26, 28) is assigned to the support, and wherein one of the bearing members (28, 50) of the respective bearing unit (22, 24) has a contact surface (34, 58) and the other one of the bearing members (26, 46) has at least one bearing surface (38, 54) includes the step of individually orientating the two bearing members (26, 28, 46, 50) of at least one bearing unit (22, 24) relative to each other as a function of the actual dimensions of the support installed and/or the component installed, fastening the two bearing members (26, 28, 46, 50) orientated relative to each other, and fastening the component to the support. The position of the support and the component relative to each other is defined by at least one bearing unit (22, 24).