Steer-by-wire column single shaft NVH packaging
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Solution Overview
Problem
Traditional steer-by-wire steering systems require multiple steering shaft components, leading to increased complexity, packaging challenges, and higher costs due to extended length and added components, making it difficult to meet NVH (Noise, Vibration, and Harshness) requirements.
Innovation Solution
A steer-by-wire steering column design featuring a single steering shaft housed within telescoping upper and lower jackets, with an integrated electric actuator and manual adjustment assembly, reducing the number of components and eliminating the need for additional shafts, while providing resistance and feedback through a direct drive system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple steering shaft components are used in traditional steer-by-wire systems, then the system can provide structural support and mechanical connection, but the device complexity increases and packaging length extends
Solution Approach 1:
The patent combines multiple steering shaft components into a single integrated steering shaft assembly. The upper and lower steering shafts are merged into one continuous shaft that extends through both the upper and lower jackets, eliminating the need for separate shaft components and reducing overall system complexity while maintaining structural integrity.
Solution Approach 2:
The single steering shaft serves multiple functions: it provides structural support, transmits steering input, and acts as a mounting structure for the electric actuator. The integrated design allows one component to fulfill multiple roles that previously required separate parts.
2Strength
If multiple steering shaft components are used, then mechanical connection is maintained, but packaging length increases and space requirements expand
Solution Approach 1:
The patent merges multiple steering shaft segments into a single continuous shaft that passes through both jackets, reducing the overall packaging length by eliminating gaps, joints, and intermediate components that would otherwise be required between separate shaft sections.
3Ease of operation
If hand wheel actuator is assembled at an angle or perpendicular to the steering column, then resistance and feedback can be provided, but additional space is required and packaging is complicated
Solution Approach 1:
The patent repositions the electric actuator from a perpendicular or angled mounting arrangement to a longitudinal alignment with the steering column axis. This dimensional change allows the actuator to be housed within the lower jacket along the length of the column rather than requiring lateral space, thereby reducing the overall footprint and simplifying packaging.
4Strength
If more than one steering shaft portion is used, then structural integrity is maintained, but manufacturing cost increases due to added complexity
Solution Approach 1:
The patent consolidates multiple steering shaft portions into a single manufactured component, reducing the number of parts that need to be produced, inventoried, and assembled. This merger decreases manufacturing complexity and associated costs while maintaining the required structural integrity through the continuous shaft design.
Data Source
AI summary
A steer-by-wire steering column includes an upper jacket extending in a longitudinal direction. The steering column also includes a lower jacket extending in the longitudinal direction, the upper jacket in telescoping engagement with the lower jacket. The steering column further includes a single steering shaft extending in the longitudinal direction and housed at least partially within the upper jacket and the lower jacket.