Non-Uniform Grooved Steering Shaft for Controlled Crash Bending
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Solution Overview
Problem
Existing steering shafts for vehicles are complex to manufacture and exhibit high fluctuations in bending characteristics, making it difficult to achieve precise bending behavior, which is crucial for preventing penetration into the passenger compartment during a crash.
Innovation Solution
A steering shaft with a tubular shaft body featuring a bending section that includes a non-uniform groove structure along its longitudinal axis, comprising grooves of varying geometry and spacing, allowing for precise adjustment of bending behavior through the design of the groove structure, material choice, and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a corrugated section is added to the steering shaft to enable deformation during crash, then the penetration prevention capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying the groove depth, width, and spacing along the longitudinal axis to create varying bending resistance. The groove structure parameters are continuously adjusted to achieve the desired bending characteristic without requiring complex multi-step manufacturing processes, thus resolving the contradiction between improved crash performance and manufacturing simplicity.
Solution Approach 2:
The patent implements local quality by creating an uneven groove structure where different sections of the shaft have different groove characteristics. This allows specific regions to have tailored bending properties - deeper grooves in areas requiring more flexibility and shallower grooves where structural integrity is needed - achieving precise bending control without overall structural complexity.
2Manufacturing precision
If a non-uniform groove structure is designed to precisely control bending behavior, then the bending characteristic precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent employs periodic action through the rolling process where a patterned roller periodically impressions grooves along the shaft as it rotates and advances. This periodic rolling action naturally creates the non-uniform groove structure with varying depths and spacings, achieving precise bending characteristics through a simple, repetitive manufacturing motion rather than complex multi-stage processing.
Solution Approach 2:
The groove structure parameters are continuously adjusted along the longitudinal axis to achieve the desired bending characteristic. By varying groove depth, width, and spacing in a controlled manner, the patent achieves precise bending behavior control while maintaining manufacturing simplicity through a single integrated rolling operation.
3Productivity
If existing manufacturing methods are used to produce corrugated steering shafts, then the production process is established, but the bending characteristic consistency deteriorates
Solution Approach 1:
The rolling process is self-regulating as the roller naturally maintains consistent pressure and geometry throughout the forming operation. The process inherently produces uniform groove patterns with high repeatability, eliminating the need for complex tooling changes or multi-step operations that previously caused bending characteristic variations. The method serves itself by using the roller's geometry to automatically ensure consistency.
Solution Approach 2:
The periodic rolling action ensures consistent groove formation through repeated, identical impressions. Each rotation of the roller produces the same groove pattern, and the periodic advance of the shaft through the roller creates uniform spacing and depth throughout the entire length, achieving high bending characteristic consistency through a simple, repetitive process.
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
The non-uniform groove structure enables precise control over the bending behavior of the steering shaft, ensuring it deforms appropriately during a crash to prevent further penetration into the passenger compartment, while also simplifying the manufacturing process.
Implementation Method 1
In the event of a vehicle crash, the steering shaft deforms, particularly compresses or bends, in the corrugated area
Implementation Method 2
By compressing or bending, the penetration of the steering shaft into the passenger compartment can be prevented or at least mitigated
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
The invention relates to a steering shaft (1) for a vehicle and to a method for producing a steering shaft of this kind. The steering shaft (1) comprises a tubular shaft body (10) which extends along a longitudinal axis (L) and has a first shaft end (11) and a second shaft end (12), wherein a bending section (13) is arranged between the first shaft end (11) and the second shaft end (12), wherein the bending section (13) has a plurality of grooves (21, 22, 23, 24), which run in the circumferential direction of the shaft body (10), for forming a groove structure, characterized in that the groove structure is of non-uniform design in the direction of the longitudinal axis (L).