Steering Intermediate Shaft Rattle Test Method
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Solution Overview
Problem
The existing methods for testing intermediate steering shaft rattle in vehicles face challenges in repeatability and isolating noise levels due to interference from other vehicle components, making it difficult to accurately determine the rattle propensity of the steering system.
Innovation Solution
A method and system involving an intermediate shaft assembly with sensors and motors to apply controlled torques and measure acceleration data, analyzing the data to determine rattle noise levels by generating a net torque signal, identifying peak acceleration values, and comparing them to a rattle index to assess the propensity for rattle noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intermediate steering shaft rattle tests are performed on a complete vehicle, then the test can be conducted in a real operational environment, but repeatability becomes very difficult and other vehicle components generate interfering noise
Solution Approach 1:
The patent segments the steering system by isolating the intermediate shaft assembly from the complete vehicle. The test setup includes only the intermediate shaft assembly with its universal joints and shaft members, separating it from other vehicle components that generate interfering noise. This segmentation allows repeatable testing by eliminating variables from other components while maintaining the specific testing of the intermediate shaft's rattle characteristics.
2Measurement precision
If tests are performed on the complete vehicle steering system, then real operational conditions can be simulated, but it becomes difficult to correctly determine noise levels of the steering system separate from other vehicle noises
Solution Approach 1:
The patent extracts the intermediate shaft assembly from the complete vehicle steering system for isolated testing. By removing the intermediate shaft assembly from the vehicle context and placing it in a dedicated test rig with controlled conditions, the measurement precision of noise levels is improved. The extraction eliminates interfering noises from other vehicle components, allowing accurate determination of the intermediate shaft's noise characteristics alone.
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
This approach enables repeatable and focused analysis of the intermediate shaft's rattle propensity, providing an objective indication of potential rattle issues and allowing for targeted design or assembly adjustments to mitigate undesirable noise.
Implementation Method 1
a first sensor coupled to the first joining member and a second sensor coupled to the second joining member, the first sensor configured to measure an acceleration of the first joining member and the second sensor configured to measure an acceleration of the second joining member
Implementation Method 2
a first sensor coupled to the first joining member and a second sensor coupled to the second joining member, the first sensor configured to measure an acceleration of the first joining member and the second sensor configured to measure an acceleration of the second joining member
Data Source
AI summary
An exemplary method for determining rattle noise of a vehicle steering system includes providing an intermediate shaft assembly including a first shaft member coupled to a second shaft member by a first joining member, a third shaft member coupled to the second shaft member by a second joining member, the first shaft member coupled to a first motor and the third shaft coupled to a second motor, providing a first sensor coupled to the first joining member and a second sensor coupled to the second joining member, sensors configured to measure an acceleration of the first joining member and the second joining member, applying a first torque and a second torque to the intermediate shaft assembly, receiving first acceleration data from the first sensor and second acceleration data from the second sensor, and analyzing the first and second acceleration data to determine a rattle noise of the intermediate shaft assembly.