Steering Shaft Ring Flag Alignment Without Special Tools

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Solution Overview

Problem

The assembly of intermediate steering shafts in vehicle steering systems is challenging due to tight environments, limited visibility, and the need for precise alignment, often requiring costly machining and specialized tools to prevent false assembly and damage to serrations.

Innovation Solution

A steering shaft assembly with a protrusion on the shaft and a ring flag that aligns rotationally and axially, allowing for precise coupling without the need for a special assembly tool, using geometric features that can be formed instead of machined, ensuring correct alignment and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a ring flag with flag is used to block the bolt and align the shaft, then false assembly is prevented, but the assembly process requires special tools and risks damaging shaft serrations

Engineering Contradiction:

Improveprevention of false assemblyVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent removes the flag component from the ring flag structure. The ring flag is designed without a protruding flag, allowing the bolt to pass through freely while the serrated inner surface provides alignment and engagement with the shaft serrations, eliminating the need for special assembly tools and reducing damage risk

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using a flag to block and align the shaft, the patent inverts the approach by using the absence of a flag combined with serrated surfaces that engage positively. The alignment is achieved through the serration geometry rather than a blocking flag mechanism

Inventive Principle:

Principle #13The other way round (Inversion)

2Stability of the object's composition

If the ring flag is pressed to position to snap into the groove, then the ring flag is retained on the shaft, but the shaft serrations may be damaged due to misalignment

Engineering Contradiction:

Improveretention of ring flagVSAvoiddamage to shaft serrations

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The ring flag's serrated inner surface automatically aligns with the shaft serrations through geometric compatibility during the pressing operation. The serrations engage positively, guiding the ring flag into correct rotational alignment and preventing damage to the shaft serrations while ensuring stable retention

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If receiving alignment geometry on the shaft is machined, then precise alignment is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvealignment precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent uses homogeneous serrated surfaces on both the shaft and ring flag that can be formed using standard stamping or forming processes rather than costly machining. The alignment precision is achieved through the geometric compatibility of these formed features, eliminating the need for expensive machined alignment geometry

Inventive Principle:

Principle #33Homogeneity

Data Source

PatentUS20240240674A1Steering shaft assembly

Publication Date: 2024.07.18 STEERING SOLUTIONS IP HOLDING CORP

AI summary

A steering shaft assembly includes a shaft having an end region to be coupled to another component with a mechanical fastener, the shaft comprising a protrusion extending radially outwardly from the shaft within the end region of the shaft. The steering shaft assembly also includes a ring flag coupleable to the end region of the shaft, the ring flag comprising a recess positioned to receive the protrusion of the shaft at a desired relative axial position of the ring flag and the shaft to rotationally align the ring flag and the shaft at a desired rotational position.