Steering Column Crossmember Connector with Bow-Shaped Metal Load Path
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices for connecting a steering column to a cross member are not optimized for load path, leading to increased weight, complexity, and logistical challenges, with limited flexibility and modular usability due to overdimensioning and high tooling costs.
Innovation Solution
A load-path-optimized device featuring a metal structure with bow-like segments and a polymeric base body for reinforcement, allowing for modular production and flexible assembly, where the metal structure is connected to the base body in both the front and rear connecting regions to ensure force introduction into the cross member via the main load path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional sheet metal shell design with metal inserts is used, then connection strength is achieved, but device weight increases and design flexibility is reduced
Solution Approach 1:
The device is divided into a base body and a separately producible connecting element that can be attached later. This segmentation allows the base body to be optimized for weight while the connecting element provides the necessary strength, resolving the contradiction between connection strength and device weight.
Solution Approach 2:
The device combines polymeric material (base body) with metallic material (connecting element) to create a composite structure. The polymeric base body reduces weight while the metallic connecting element ensures connection strength, effectively resolving the weight-strength contradiction.
2Ease of manufacture
If injection molding directly on cross member is used, then assembly is simplified, but tooling costs increase and modular usability is reduced
Solution Approach 1:
The device is segmented into a base body and a separate connecting element that can be produced independently and then assembled. This eliminates the need for complex injection molding tools while maintaining assembly simplicity, as the pre-assembled connecting element can be easily attached to the base body.
Solution Approach 2:
The connecting element is pre-assembled or pre-positioned on the base body before final installation on the cross member. This preliminary action simplifies the final assembly process and reduces the complexity of tooling required during production.
3Reliability
If overdimensioning is applied to meet safety requirements, then safety is ensured, but device weight increases and logistical efficiency decreases
Solution Approach 1:
Instead of uniformly overdimensioning the entire device, the invention applies high-strength materials and optimized structures only in the connecting element where strength is critically needed. The base body can be lighter, achieving safety requirements without unnecessary weight increase.
Solution Approach 2:
The connecting element features a bow-shaped curved structure that efficiently distributes and redirects forces along its arc. This curved geometry provides high strength-to-weight ratio, ensuring safety while minimizing device weight compared to straight or blocky designs.
4Strength
If complex assembly structures are used, then connection strength is achieved, but assembly time increases and modular usability is reduced
Solution Approach 1:
The device is segmented into a base body and a separate connecting element designed for quick attachment. This segmentation enables the connecting element to be pre-assembled or pre-positioned, significantly reducing on-site assembly time while maintaining connection strength through the specialized connecting element design.
Solution Approach 2:
The connecting element is prepared in advance (pre-assembled or pre-positioned) before final installation. This preliminary action eliminates complex assembly steps during final installation, reducing assembly time while ensuring connection strength is already established in the pre-assembled component.
Data Source
AI summary
A device for connecting a steering column to a cross member positioned between two A-pillars. The device comprises a front connecting region, a cross member-accommodating region, and a rear connecting region. The device comprises at least one metal structure, which is designed as a bow or comprises at least one such bow, extending from the front connecting region to the rear connecting region. A base body supports the metal structure. The metal structure is substantially the main load path for introducing force into the cross member. The base body is connected to the metal structure in at least the front connecting region and rear connecting region, in the direction of the main load path.