Steering Shaft Sleeve Segmentation for Manufacturing Consistency
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Solution Overview
Problem
The existing steering column assemblies exhibit substantial manufacturing variability due to custom-fit injection molded bushings, leading to inconsistent performance and quality control challenges.
Innovation Solution
A telescopically translatable steering shaft assembly is designed with a steering shaft and a sleeve featuring a plurality of splines and elongate members, which reduces variability by providing a pre-formed sleeve that facilitates sliding motion and is assembled onto the steering shaft, thereby minimizing manufacturing inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-fit injection molded bushings are used, then a precise fit is achieved, but manufacturing variability increases substantially
Solution Approach 1:
The invention divides the bushing into multiple pre-formed bushing segments that are assembled onto the steering shaft in a standardized sequence. Each segment corresponds to a specific spline and can be manufactured independently using standardized processes, eliminating the need for custom-fit injection molding while maintaining precise fit through the segmented structure and assembly sequence.
2Manufacturing precision
If custom-fit injection molded bushings are used, then fit precision is improved, but production time increases
Solution Approach 1:
The bushing segments are pre-formed and pre-assembled in a standardized sequence before being installed on the steering shaft. This preliminary preparation allows for efficient batch manufacturing and assembly, reducing production time compared to custom-fit injection molding performed on each individual steering shaft assembly.
3Reliability
If pre-formed sleeves with splines are used, then manufacturing variability is reduced, but assembly complexity increases
Solution Approach 1:
The sleeve is segmented into multiple bushing segments that correspond to individual splines. Each segment can be manufactured using standardized processes and assembled in a defined sequence, reducing manufacturing variability while keeping assembly systematic and manageable through the structured segmentation approach.
Data Source
AI summary
A telescopically translatable steering shaft assembly includes a steering shaft and a sleeve. The steering shaft defines a first plurality of splines extending from a first steering shaft end towards a second steering shaft end along a steering column axis. The sleeve has a first elongate member that extends between a first sleeve end that is disposed about the first steering shaft end and a second sleeve end that is disposed about an end of the first plurality of splines. The first elongate member is disposed on a first spline of the first plurality of splines.