Telescopic Intermediate Shaft Structure for Collision Collapse Stroke
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Solution Overview
Problem
Conventional intermediate shafts in large-sized or high-performance vehicles face issues with reduced power transmission stability and insufficient collapse stroke during collisions, leading to potential removal of the shaft.
Innovation Solution
An intermediate shaft design featuring a first hollow shaft with grooves and press-in portions to accommodate a second hollow shaft, which includes a first slip member with press-in portions to enhance shock absorption and prevent removal, and a second slip member with rolling balls for additional shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the length of the intermediate shaft is extended to accommodate larger vehicles with longer bonnets, then the distance between steering column and steering gear is covered, but the stability of power transmission is lowered and collapse stroke is insufficient
Solution Approach 1:
The intermediate shaft is divided into multiple segments (first intermediate shaft, second intermediate shaft, third intermediate shaft) that can slide relative to each other. This segmentation allows the shaft to maintain overall length for power transmission while enabling controlled collapse through relative movement between segments during collision, thus resolving the contradiction between length and stability.
Solution Approach 2:
The intermediate shaft transitions from a static rigid structure to a dynamic telescopic structure. The slip members enable the shaft segments to move relative to each other under impact force, providing controlled collapse stroke while maintaining structural integrity for power transmission during normal operation.
2Ease of manufacture
If a simple hollow shaft structure is used, then manufacturing is easy, but the shaft may be removed during collision or abnormal operation
Solution Approach 1:
Press-in portions are pre-formed on the inner circumference of the hollow shaft portions before assembly. These press-in portions create preliminary mechanical interference with the slip members, preventing removal during collision or abnormal operation while maintaining ease of manufacture through pre-forming operations.
Solution Approach 2:
The shaft structure incorporates localized press-in portions at specific positions on the inner circumference of hollow shaft portions. This local quality enhancement provides anti-removal functionality only where needed, without complicating the overall simple hollow shaft structure or manufacturing process.
3Reliability
If press-in portions are formed on the inner circumference of the first hollow shaft portion, then shock absorption efficiency is improved and collapse stroke is secured, but the structure becomes more complex
Solution Approach 1:
Press-in portions are formed only at specific localized positions on the inner circumference of the hollow shaft portions rather than uniformly throughout. This provides shock absorption functionality at critical locations while minimizing overall structural complexity and maintaining manufacturing simplicity.
Solution Approach 2:
The press-in portions are pre-formed during manufacturing, incorporating the shock absorption features into the base manufacturing process. This preliminary action adds shock absorption capability without requiring additional complex assembly steps or structures.
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 design improves collapse stroke and shock absorption efficiency, ensuring safety by maintaining the shaft's integrity during collisions and abnormal operations.
Implementation Method 1
a first press-in portion may be formed on an inner circumference of the first hollow shaft portion to protrude therefrom, thereby pressing and supporting the first slip member... the first press-in portion may provide a resistance force to the first slip member against an impact force
Implementation Method 2
a second press-in portion may be formed on an inner circumference of an end of the first hollow shaft portion to prevent removal of the first slip member
Data Source
AI summary
An intermediate shaft includes a first hollow shaft portion in which a plurality of grooves are formed in a longitudinal direction thereof, a second hollow shaft portion coupled at one end thereof to a first slip member, provided to be accommodated inside the first hollow shaft portion, and slipped into the first hollow shaft portion when a collision occurs, and a shaft portion to which a second slip member is coupled, provided to be accommodated inside the second hollow shaft portion, and slipped into the second hollow shaft portion when the collision occurs. A first press-in portion is formed on an inner circumference of the first hollow shaft portion to protrude therefrom, thereby pressing and supporting the first slip member.