Stamped Shift Assembly Bracket for Compact Steering Columns
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Solution Overview
Problem
Current shift assemblies in vehicles are bulky and costly due to numerous cast and machined components, necessitating a reduction in size and parts count to lower costs while improving performance.
Innovation Solution
A steering column assembly with a gear shift assembly featuring a shift assembly bracket and shift shaft assembly, including a column mounting portion, cradle portion, and cable mounting portion, which integrates a shift shaft and shifter cup to reduce complexity and size, while maintaining functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous cast and machined components are used in the shift assembly, then the shift assembly can maintain traditional functionality, but the cost and size of the shift system increase significantly
Solution Approach 1:
The patent combines multiple traditional cast and machined components into a single stamped shift assembly bracket. This bracket integrates the column mounting portion, cradle portion with sidewalls, and cable mounting portion, thereby reducing the total number of parts while maintaining the necessary functional capabilities for gear shift operation and steering column attachment
Solution Approach 2:
The stamped shift assembly bracket serves multiple functions simultaneously: it provides structural support for the steering column, creates the cradle for the shift shaft assembly, and offers mounting points for control cables. This multi-functionality eliminates the need for separate components for each function, reducing overall system complexity
2Strength
If traditional cast and machined components are used, then the shift assembly can provide adequate structural support, but the overall size and profile of the shift system increase
Solution Approach 1:
The patent employs a stamped metal bracket that uses thin-walled construction with strategically placed reinforcement features. The stamped forming process creates integrated ribs and thickened sections where structural strength is needed, while maintaining thin walls in non-critical areas, thereby providing adequate structural support with minimized material usage and compact size
3Reliability
If numerous components are used in the shift assembly, then traditional shift functionality can be maintained, but the manufacturing cost increases significantly
Solution Approach 1:
The patent consolidates multiple traditionally manufactured components into a single stamped part. This merging eliminates the need for separate casting and machining operations for each component, reducing manufacturing steps, tooling requirements, and assembly operations, thereby significantly lowering production costs while maintaining functional reliability
Solution Approach 2:
The stamped shift assembly bracket replaces expensive cast and machined components with a more economical stamped metal construction. The stamping process is inherently more cost-effective for high-volume production, using less material and requiring less post-processing compared to traditional casting and machining operations
Data Source
AI summary
A steering column assembly that includes an upper jacket and a gear shift assembly. The upper jacket extends along a steering column axis. The gear shift assembly includes a shift assembly bracket and shift shaft assembly. The shift assembly bracket has a column mounting portion that is operatively connected to the upper jacket and a cradle portion extends from the column mounting portion. The cradle portion has a first sidewall and a second sidewall each extending from a base. The shift shaft assembly extends at least partially through the first sidewall and the second sidewall.