Modular Extruded Steering Column with Longitudinal Slot
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Solution Overview
Problem
The existing methods for manufacturing steering columns using extruded profiles are inefficient and require significant processing effort, making it challenging to produce steering columns that are cost-effective, lightweight, and adaptable to different vehicle installation situations while maintaining structural integrity and safety features.
Innovation Solution
A method involving the production of steering columns with an inner and outer casing tube, where the outer casing tube has a longitudinal slot and a tensioning device that can switch between release and fixing positions, allowing for adjustable component lengths and modular design using machining operations to create functional elements, ensuring the profile structure remains intact and supporting the steering shaft effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extruded profiles are used for steering column production, then production costs are reduced and weight is decreased, but machining effort and processing complexity increase
Solution Approach 1:
The steering column is divided into modular sections (inner sleeve, outer sleeve, functional elements) that can be independently manufactured via extrusion and then assembled. This segmentation allows each module to be produced cost-effectively using extrusion while minimizing the need for complex post-machining operations on the entire structure.
Solution Approach 2:
The extruded profile design incorporates multiple functional elements (mounting points, guide slots, bearing seats) directly into the profile structure itself, allowing a single extruded component to serve multiple functions that would traditionally require separate parts and extensive machining operations.
2Adaptability or versatility
If steering columns are designed for different vehicle platforms, then adaptability is improved, but production efficiency and cost-effectiveness deteriorate due to multiple variants
Solution Approach 1:
The steering column design incorporates adjustable and configurable elements (such as adjustable sleeve lengths, configurable mounting positions) that allow the same basic extruded profile structure to be adapted to different vehicle platforms without requiring completely different designs, thereby maintaining production efficiency while achieving versatility.
Solution Approach 2:
The modular segmentation of the steering column into standardized extruded modules allows for flexible configuration across different vehicle platforms. By assembling different combinations of the same basic modules, the system achieves adaptability to various platforms while maintaining cost-effective standardized production processes.
3Strength
If the outer sleeve is designed to completely enclose the steering shaft by more than 270°, then structural rigidity is improved, but material usage and manufacturing complexity increase
Solution Approach 1:
The outer sleeve is designed with varying levels of enclosure and structural reinforcement at different locations around the steering shaft. Rather than uniformly enclosing 360°, the sleeve provides enhanced rigidity (more than 270° enclosure) specifically in the critical areas where structural support is needed, while reducing material usage in less critical regions.
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 enables the cost-effective production of steering columns with adjustable lengths, ensuring a high level of rigidity and safety features, such as impact energy absorption, while maintaining a modular design that reduces processing effort and production costs, allowing for identical parts to be used across different vehicle platforms.
Implementation Method 1
Manufacturing a single blank of the outer casing tube in an extrusion process, which has the longitudinally continuous slot
Data Source
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AI summary
The invention relates to a method for producing a steering column for a motor vehicle, wherein the steering column comprises an inner jacket tube (2) for accommodating a steering shaft (3, 11) in such a way that the steering shaft can be rotated about the longitudinal axis thereof, and an outer jacket tube (1), which accommodates the inner jacket tube (2), wherein the outer jacket tube (1) has a longitudinal slot (21) extending in the direction of the longitudinal axis, wherein a clamping device (8), which can be switched between a releasing position, in which the inner jacket tube (2) can be moved in relation to the outer jacket tube (1), and a fastening position, in which the inner jacket tube (2) is fastened in relation to the outer jacket tube (2), wherein the clamping device (8) comprises a clamping shaft (27), which is fed through a cut-out in the outer jacket tube transversely to the longitudinal axis, and wherein the longitudinal slot (21) has a greater width in the releasing position than in the fastening position, characterized in that the method comprises the following steps: a) producing at least one individual blank of an outer jacket tube (1) and/or of an inner jacket tube (2) in an extrusion method, b) cutting the at least one individual blank to a required component length, c) producing a predefined number of cut-outs at a predefined given distance (L, L1, L2) from an end of the at least one blank by means of a chip-removal operation in order to form functional elements (31) in the outer jacket tube (1), wherein the specified distance (L, L1, L2) is independent of the length of the blank cut in step b), g) completing the steering column by attaching further parts.