Steering Column Bracket Welding to Large Diameter Portion
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Solution Overview
Problem
The conventional steering column design faces challenges in maintaining appropriate axial sliding resistance between the inner and outer columns, leading to variations in interference fit and increased manufacturing costs due to residual stress-induced deformation from welding, which affects the absorption of impact loads during secondary collisions.
Innovation Solution
The design incorporates a tubular outer column with a press-fitted inner column and an adjacent large diameter portion, where the column-side bracket is welded to the outer column's adjacent large diameter portions, reducing deformation and maintaining consistent sliding resistance by limiting contact points between the inner and outer columns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the column-side bracket is welded to the outer column at the press-fitted portion, then the bracket is securely fixed, but residual stress-induced deformation occurs affecting sliding resistance
Solution Approach 1:
The outer column is divided into distinct functional zones: a press-fitted portion for inner column insertion and an adjacent large diameter portion for bracket welding. This segmentation isolates the welding operation from the press-fit interface, preventing residual stress from affecting sliding resistance while maintaining secure bracket fixation.
Solution Approach 2:
The outer column exhibits local quality variation through different diameter portions. The adjacent large diameter portion has increased diameter specifically at the welding location to accommodate the column-side bracket, while the press-fitted portion maintains its original dimensions for proper interference fit. This localized structural differentiation resolves the contradiction between secure fixing and precision maintenance.
2Stability of the object's composition
If the inner and outer columns have extensive contact area, then structural stability is improved, but manufacturing complexity increases due to alignment requirements
Solution Approach 1:
The contact interface between inner and outer columns is segmented into discrete contact locations rather than continuous contact. The inner column has protrusions that create localized contact points with the outer column's inner surface, maintaining stability through distributed point contacts while simplifying manufacturing by reducing alignment sensitivity.
Solution Approach 2:
The contact between inner and outer columns is concentrated at specific locations rather than distributed uniformly. The inner column features protrusions that create localized high-contact-area regions, providing sufficient structural stability while reducing the overall complexity of alignment and fitting during manufacturing.
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 configuration stabilizes the absorption of impact loads during secondary collisions by maintaining appropriate sliding resistance and reducing manufacturing complexity and costs by minimizing the need for precise alignment and fitting accuracy.
Implementation Method 1
the impact load during the secondary collision is absorbed due to the outer-circumferential surface of the inner column 9 and the inner-circumferential surface of the outer column 10 sliding in the axial direction
Implementation Method 2
The outer-circumferential surface of the inner column 9 comes in contact with (fits with) the inner-circumferential surface of the outer column 10 with an interference fit at only portions corresponding to the top portion of each of the ridges 11
Data Source
AI summary
The outer column has a press-fitted portion into which the inner column is press-fitted on the inner-diameter side, and an adjacent large diameter portion arranged in a location adjacent to the press-fitted portion in the axial direction and having an inner-diameter dimension larger than an inner-diameter dimension of the press-fitted portion. The inner-circumferential surface of the press-fitted portion and the outer-circumferential surface of the inner column come in contact with each other with an interference directly or via another member at only a plurality of contact locations separated in the circumferential direction. The column-side bracket is welded to an outer-circumferential surface of the adjacent large diameter portion with at least a part of the column-side bracket located on the outer-diameter side of the press-fitted portion.