Steering Shaft Alignment Using Serrated Phasing Connectors
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Solution Overview
Problem
The challenge lies in accurately aligning and mounting a steering shaft with universal joints in an adjustable steering column to ensure optimal phasing angles, minimizing torque inconstancy and achieving a neutral steering wheel position, especially in heavy goods vehicles where driver preferences vary and correct alignment is critical for direct vision and smooth rotation.
Innovation Solution
A steering shaft design featuring serrated connectors and mounting aids, including a sleeve with a protrusion and axial slot, allows for precise alignment and clamping of universal joints, ensuring a preset phase angle for smooth torque transmission and error-free assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If universal joints are mounted with proper phasing angle to minimize torque inconstancy, then torque transmission smoothness is improved, but alignment precision and assembly accuracy are worsened due to the complexity of achieving correct rotational orientation
Solution Approach 1:
The patent applies preliminary action by pre-configuring the mounting aid with a specific rotational orientation relative to the steering shaft connector. The mounting aid includes alignment features (such as protrusions and slots) that automatically guide the universal joint into the correct phased position during assembly, eliminating the need for complex post-assembly alignment adjustments and ensuring accurate phasing angle without requiring high skill level from assemblers
Solution Approach 2:
The mounting aid serves as an intermediary device between the steering shaft connector and the universal joint. It includes a body with a first opening for receiving the connector and a second opening for receiving the universal joint, with alignment features that mediate the rotational orientation relationship. This intermediary structure ensures the correct phasing angle is achieved through its built-in geometric constraints rather than requiring direct precision alignment between the connector and universal joint
2Adaptability or versatility
If steering wheel position is made adjustable to meet driver preferences, then adaptability is improved, but assembly complexity and alignment difficulty are worsened
Solution Approach 1:
The patent applies segmentation by dividing the steering shaft into modular components: the steering shaft connector, the mounting aid, and the universal joint assembly. This segmentation allows each component to be independently manufactured and assembled, with the mounting aid serving as a standardized interface that simplifies the assembly process despite the overall system's adjustability features. The modular design reduces assembly complexity by allowing straightforward connection of segments rather than requiring complex integrated adjustments
3Measurement precision
If neutral position alignment is made highly precise to ensure correct wheel alignment, then steering accuracy is improved, but assembly time and operational complexity are worsened
Solution Approach 1:
The mounting aid acts as an intermediary that pre-encodes the correct neutral position alignment into its structure. The alignment features (protrusions, slots, or other geometric constraints) are built into the mounting aid body, automatically guiding the universal joint and steering shaft connector into the correct relative positions. This eliminates the need for time-consuming measurement and adjustment operations during assembly, as the correct alignment is achieved through the physical constraints of the intermediary device itself
Solution Approach 2:
The correct neutral position alignment is prepared in advance during the design and manufacturing of the mounting aid. The alignment features are pre-configured with the exact geometric relationships needed for correct neutral position. During assembly, this pre-prepared alignment information is simply transferred to the assembled components, eliminating the need for time-consuming on-site measurement and adjustment operations
Data Source
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AI summary
It is an aspect of the present invention to alleviate, at least partially, the problems discussed above by a steering shaft comprising: at one outer end a inputs shaft of steering gear connector connecting the first universal joint to the inputs shaft of steering gear, at an intermediate position of the steering shaft, a steering shaft connector connecting the second universal joint to the first universal joint at a first preset phase angle; and at an opposite outer end a wheel connector connecting the second universal joint to the steering wheel; wherein the steering shaft connector is provided with a serrated interior that coincides with a correspondingly serrated shaft part of the first or second universal joint, for providing a discrete rotary position of the steering shaft connector relative to the serrated shaft part; and a first mounting aid for defining a relative rotary position of the steering shaft connector relative to the serrated shaft part.