Steering Shaft Flag Device for Clamp Yoke Alignment
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Solution Overview
Problem
The assembly of a steering shaft into a clamp yoke is complicated by tight spaces and poor lighting, requiring precise axial and rotational alignment, which is often hindered by the need to move the vehicle during assembly, leading to potential improper coupling.
Innovation Solution
A flag device with a body configured to fit into a recessed pocket on the steering shaft and a radially extending flag that obstructs the fastener opening in the clamp yoke until the steering shaft is fully inserted, ensuring proper alignment and preventing premature fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the steering shaft is inserted into the clamp yoke without an alignment mechanism, then the assembly process is simpler, but proper axial and rotational alignment cannot be ensured
Solution Approach 1:
The flag device is pre-positioned on the steering shaft to provide visual and tactile alignment indicators before the actual assembly operation. The flag extends radially outward to obstruct the fastener opening, creating a preliminary alignment check mechanism that guides the assembler through the insertion process.
Solution Approach 2:
The flag device acts as an intermediary element between the steering shaft and the clamp yoke. It provides a visual and tactile intermediary indicator that mediates the alignment process, allowing the assembler to verify proper insertion without directly observing the internal alignment state.
2Ease of operation
If the assembly is performed in tight spaces with poor lighting, then the assembly process can be completed, but proper alignment becomes difficult to achieve
Solution Approach 1:
The flag device provides visual feedback through its radial extension and obstruction of the fastener opening, creating a visible alignment indicator that can be detected in poor lighting conditions. The flag's presence or absence at the fastener opening provides clear visual confirmation of proper alignment.
Solution Approach 2:
The flag device provides self-aligning characteristics through its geometric configuration. The flag's radial extension and the recessed pocket configuration create a self-verifying alignment mechanism that automatically indicates when the steering shaft is properly inserted, eliminating the need for external alignment tools.
3Productivity
If the steering shaft is not fully inserted to the predetermined position, then the assembly process is faster, but improper coupling occurs
Solution Approach 1:
The flag device provides immediate feedback to the assembler about the insertion status of the steering shaft. When the shaft is properly inserted, the flag moves to a position where it no longer obstructs the fastener opening, providing clear feedback that confirms correct assembly and prevents premature or improper fastening.
Data Source
AI summary
A steering shaft assembly includes a steering shaft extending along a central longitudinal axis between opposite first and second end portions terminating at respective first and second ends. A recessed pocket extends axially into the first end. The first end portion is configured for receipt in a through bore of a clamp yoke. A flag device has a body configured for receipt in the recessed pocket and a flag extending radially outwardly from the body. The flag is configured to obstruct a fastener opening in the clamp yoke until the steering shaft is inserted into the through bore to a predetermined insertion position.