Steering Sensor Casing Keying for Assembly Positioning
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Solution Overview
Problem
Current motor vehicle steering systems face difficulties in accurately positioning and orienting sensor casings during assembly, leading to potential assembly errors due to smooth joint planes and lack of visual orientation cues, especially with circular-shaped sensor casings.
Innovation Solution
A 'keying' system is introduced, where complementary relief shapes on one casing match with corresponding hollow shapes on the other, facilitating precise positioning and orientation without additional machining or material, using shapes like ribs, pins, and notches that can be molded directly into the casings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If smooth joint planes are used for casing assembly, then manufacturing simplicity is improved, but positioning precision and orientation accuracy deteriorate
Solution Approach 1:
The patent applies local quality by introducing localized geometric features (protrusions and recesses) at specific locations on the casing surfaces, while the rest of the joint planes remain smooth. This allows the majority of the surface to maintain simplicity for manufacturing, while specific local areas provide the necessary positioning and orientation functions.
Solution Approach 2:
The patent employs asymmetry by designing non-circular protrusions and corresponding recesses with specific geometric characteristics that allow only one correct orientation during assembly. This asymmetric keying system ensures precise positioning and orientation without requiring complex manufacturing processes across the entire joint surface.
2Ease of manufacture
If circular-shaped sensor casings are used, then manufacturing simplicity is improved, but visual orientation capability deteriorates
Solution Approach 1:
The patent resolves this contradiction by introducing asymmetric protrusions and recesses on the circular casings. These features break the rotational symmetry, providing clear visual and tactile cues for correct orientation during assembly, while the overall circular shape and molding process remain simple and cost-effective.
3Adaptability or versatility
If trial and error assembly method is used, then adaptability is improved, but assembly time and productivity deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-configuring the protrusions and recesses during the casing manufacturing process. This preliminary structuring eliminates the need for trial and error during assembly, as the features guide correct positioning and orientation from the first attempt, significantly reducing assembly time while maintaining flexibility for different sensor types.
Data Source
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AI summary
The device has complementary units (9) that cooperate in a zone of a junction plane (P) during assembling of a torque sensor casing on a main steering-gear box (2) to position and direct the sensor casing with respect to the steering-gear box. A relief form of the sensor casing is obtained directly by molding during manufacturing of the sensor casing. A hollow form of the main steering-gear box is obtained by molding, where the main steering-gear box is made of aluminum.