Steering Column Pivot Splines for Compact Lash-Free Adjustment
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Solution Overview
Problem
Steering column assemblies require significant packaging space and multiple components that need staking, welding, or other processes for adjustment, leading to inefficiencies in design and assembly.
Innovation Solution
A steering column assembly featuring a lower jacket, mounting bracket, and rake bracket assembly with pivot bushings and fasteners that form mating splines and serrations to facilitate adjustment and alignment without welding, reducing the need for pre-serrated brackets and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional steering column adjustment features are used, then steering column adjustment is enabled, but packaging space is significantly increased
Solution Approach 1:
The patent combines the rake bracket and mounting bracket into a single integrated assembly where the rake bracket is formed as part of the mounting bracket structure. This merging eliminates separate adjustment mechanisms and reduces the overall packaging space required while maintaining steering column adjustment functionality through the integrated pivot axis design
2Strength
If multiple components with welding or staking processes are used, then structural strength is improved, but assembly complexity and production cost increase
Solution Approach 1:
The pivot fastener is designed with self-forming spline features that create mating splines directly in the mounting bracket during the fastening process itself. This self-service mechanism eliminates the need for separate staking or welding operations to create engagement features, reducing assembly complexity while maintaining structural strength through the formed spline connection
Solution Approach 2:
The pivot fastener includes pre-formed splines that automatically create mating splines in the mounting bracket during installation. This preliminary action of forming the engagement features as part of the assembly process eliminates subsequent staking or welding steps, reducing both assembly complexity and production cost while ensuring proper structural strength
3Reliability
If pre-serrated brackets are used, then rotational lash is eliminated, but manufacturing cost and complexity increase
Solution Approach 1:
The mounting bracket and rake bracket are designed with self-forming spline features that create precise mating splines during the fastening process. This self-service mechanism automatically eliminates rotational lash without requiring expensive pre-serrated brackets, reducing manufacturing cost while maintaining the reliability of lash-free rotational engagement
4Strength
If multiple separate brackets and fastening processes are used, then structural robustness is achieved, but production time and cost increase
Solution Approach 1:
The integration of the rake bracket into the mounting bracket structure allows multiple structural functions to be achieved in a single component assembly. This merging maintains structural robustness while enabling faster assembly since fewer separate parts need to be handled and fastened, directly improving productivity
Solution Approach 2:
The pivot fastener performs multiple functions including creating mating splines, establishing structural connections, and eliminating rotational lash all in a single installation action. This preliminary action of accomplishing multiple structural requirements simultaneously maintains robustness while significantly reducing assembly time and improving production efficiency
Data Source
AI summary
A method of assembling a steering column assembly includes pressing a first pivot bushing into a first rake bracket first opening of a first rake bracket and inserting a first pivot fastener into the first pivot bushing and into a first mounting bracket opening of a first mounting bracket arm of a mounting bracket. The method further includes displacing material of the first mounting bracket arm with first splines of the first pivot fastener to form first mating splines within the first mounting bracket opening.