Steering Shaft Checking Tool for Dimensional Verification
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Solution Overview
Problem
In automotive vehicle assembly, it is challenging to ensure that the steering column shaft and intermediate shaft are properly interconnected in the correct dimensional relationship due to the complexity and difficulty in measuring the connection position, which can lead to assembly errors and safety issues.
Innovation Solution
A tool with a housing, movable supports, an actuator, and sensors is used to measure the dimensional relationship between the steering column shaft and intermediate shaft, providing an easy-to-use solution for determining if the connection is within an acceptable range, including a pistol grip design with linear encoder and light indicators for proper positioning and measurement validation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual measurement methods are used to check steering shaft interconnection, then the assembly process can be completed quickly, but the measurement accuracy and reliability are insufficient
Solution Approach 1:
The patent replaces manual visual inspection and simple mechanical gauges with electronic sensors (optical or electromagnetic) and digital encoders to measure the dimensional relationship between steering shafts. This substitution of mechanical measurement systems with electronic sensing systems achieves high measurement precision while maintaining reasonable device complexity through integrated electronic circuits and digital processing.
Solution Approach 2:
The patent introduces a micrometer mechanism as an intermediary device that translates the complex three-dimensional spatial relationship between steering shafts into a single linear dimensional measurement. The micrometer acts as a mediator that converts difficult-to-measure angular and positional relationships into easily quantifiable linear displacement, thereby achieving accurate measurement without requiring complex multi-axis sensing systems.
2Productivity
If the steering shafts are interconnected quickly during assembly, then productivity increases, but the risk of improper connection and assembly errors increases
Solution Approach 1:
The patent implements immediate feedback through electronic sensors that continuously monitor the dimensional relationship between steering shafts during the assembly process. When the shafts are properly interconnected, the sensor detects the correct dimensional relationship and provides immediate confirmation (such as a visual or audible signal). This real-time feedback allows assembly workers to quickly verify proper connection without slowing down the assembly process, thereby maintaining high productivity while ensuring high reliability.
Solution Approach 2:
The patent incorporates preliminary positioning features and guide structures that pre-align the steering shafts before the final interconnection step. These preliminary actions ensure that the shafts are approximately in the correct position before the critical measurement and locking steps, reducing the risk of improper connection and making the final assembly step more reliable and faster.
3Ease of operation
If simple checking tools are used, then the tool is easy to operate, but the tool cannot accurately determine proper dimensional relationship
Solution Approach 1:
The patent designs the measurement tool to be self-aligning and self-measuring, where the sensor automatically positions itself relative to the steering shafts and performs the measurement without requiring complex manual setup or adjustment by the operator. The tool incorporates automatic reference establishment and self-calibration features, allowing any trained worker to use it easily while maintaining high measurement precision through automated sensing and processing.
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
The tool effectively ensures proper interconnection of the steering shafts by providing accurate dimensional measurements and clear indications of acceptable or non-acceptable connections, enhancing assembly quality and safety.
Implementation Method 1
The first sensor is a linear encoder
Implementation Method 2
A first biasing means is disposed between the first and second supports for normally biasing in the second support to a normal position spaced from the first support
Implementation Method 3
A first linear bearing is carried on one of the first or second supports. A shaft, carried on the other of the first and second supports, slidably engages the first linear bearing
Data Source
AI summary
A tool is used to determine whether or not a dimension between two surface features on two joined work pieces is within an acceptable range. The tool includes housing, first and second supports carried on the housing and carrying fingers which engage the surface features in a dimensional measurement position. An actuator and linkage displaces the supports relative to each other to bring the fingers into engagement with the first and second surface features on the work pieces. A first sensor is carried on the housing for measuring the dimension between the first and second fingers when the first and second supports are fully displaced relative to each other. The first sensor sends a dimensional measurement signal to a controller which compares the measurement signal with predetermined acceptable and non-acceptable dimensions.