Steering Column Defect Detection Using Blocked Force Sensors
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Solution Overview
Problem
Current methods for detecting defects in power adjustable steering columns, such as audible noise verification, are subjective and inefficient, leading to high reject rates and warranty issues due to their reliance on human evaluation and accelerometers that may not identify all defects.
Innovation Solution
A system utilizing a power adjustable steering column, a steering column stand, blocked force sensors, a control system with a software program and computing device, and data acquisition to measure dynamic forces during adjustment operations, determining if the steering column operates within predetermined limits, and identifying defects based on these measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human evaluation and accelerometers are used for audible noise verification, then the detection process is simple to implement, but the measurement precision and reliability of defect detection deteriorate due to subjectivity and inability to identify all defects
Solution Approach 1:
The patent replaces the mechanical/acoustic measurement system (accelerometers and human evaluation) with an electrical measurement system. Blocked force sensors measure electrical signals related to audible noise through the relationship between mechanical vibration and electrical response, enabling more precise and objective defect detection without relying on human subjectivity or limited accelerometer capabilities.
Solution Approach 2:
The patent introduces blocked force sensors as an intermediary measurement device that captures the relationship between audible noise and dynamic forces. These sensors act as a mediator that translates mechanical vibrations and noise into measurable electrical signals, providing a more comprehensive detection mechanism than direct acoustic measurement alone.
2Reliability
If subjective human evaluation is used for audible noise verification, then the device complexity is low, but the reliability of defect detection deteriorates leading to high reject rates and warranty issues
Solution Approach 1:
The patent replaces subjective human evaluation with an automated electrical measurement system using blocked force sensors. This substitution eliminates human subjectivity and variability, providing consistent, objective, and reliable defect detection that reduces false reject rates and warranty issues while maintaining manageable system complexity.
Solution Approach 2:
The measurement system is designed to be self-evaluating through automated data acquisition and analysis. The blocked force sensors continuously monitor dynamic forces during steering column operation, and the system automatically compares measurements against predetermined limits to identify defects, eliminating the need for subjective human judgment and improving reliability.
3Productivity
If traditional audible noise verification methods are used, then the ease of operation is high, but the productivity deteriorates due to inefficiency in defect detection
Solution Approach 1:
The patent implements continuous measurement and monitoring during steering column adjustment operations. The blocked force sensors continuously capture dynamic force data throughout the adjustment cycle, enabling real-time defect detection without interrupting the production flow. This continuous measurement approach significantly improves detection efficiency compared to intermittent or post-production inspection methods.
Solution Approach 2:
The patent replaces inefficient manual or post-production verification methods with an automated electrical measurement system that operates in real-time during production. This substitution enables seamless integration into the manufacturing process, improving productivity while maintaining operational simplicity through automated data collection and analysis.
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 approach provides a robust, objective mechanism for defect detection, differentiating between acceptable and defective steering columns, reducing reject rates and ensuring compliance with customer specifications, suitable for mass production.
Implementation Method 1
The blocked force sensor is connected to the steering column running noise stand base and configured to measure dynamic forces generated by the steering column while the system is translated during an adjustment operation
Data Source
AI summary
A method for detecting steering column defects. The method includes applying a voltage to a steering column mounted on a steering column stand, to cause the steering column to perform an adjustment operation. The method also includes receiving, from at least one force sensor, a plurality of force measurements during performance of the adjustment operation. The method also includes determining whether the steering column is operating within predetermined parameters based on the plurality of force measurements. The method also includes, in response to a determination that the steering column is not operating within the predetermined parameters, identifying the steering column as including at least one defect.