Steering Wheel Armature Segmentation for Styling Flexibility
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Solution Overview
Problem
The high cost and complexity of designing multiple steering wheel models arise from the need for unique structural components and extensive re-validation of each design, driven by the requirement for distinct force/deflection characteristics and styling variations.
Innovation Solution
A steering wheel design featuring a rigid internal armature with a hub, rim, and two spokes, combined with an external compressible material overlay that allows for styling variations without altering the force/deflection characteristics, using a metal armature and polyurethane overmold to add additional spokes for design flexibility without increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a new structural component or armature is designed for each newly styled steering wheel, then the steering wheel can achieve the desired force/deflection characteristic and styling, but the manufacturing cost increases significantly due to unique tooling and engineering research
Solution Approach 1:
The steering wheel is divided into two functional segments: a standardized structural component (armature) that provides force/deflection characteristics, and a cosmetic finish component that provides styling variations. This segmentation allows independent optimization of each part - the armature remains unchanged across models while cosmetic finishes can be varied to achieve different steering wheel styles without requiring new tooling for each variation.
Solution Approach 2:
The structural armature is designed as a universal component that serves multiple vehicle models and steering wheel styles. By making the armature multi-functional and applicable across different steering wheel configurations, the manufacturer eliminates the need for unique tooling for each model, thereby reducing manufacturing costs while maintaining the required performance characteristics.
2Reliability
If a new structural component is designed for each steering wheel style, then the force/deflection characteristic can be optimized, but the device complexity and development time increase due to re-validation requirements
Solution Approach 1:
The steering wheel design is segmented into performance-critical structural elements (armature) and non-critical cosmetic elements (finish). This segmentation allows the structural component to be validated once and reused across multiple designs, eliminating the need for repeated validation processes while maintaining reliable force/deflection characteristics.
Solution Approach 2:
The structural armature is designed and validated in advance as a standardized component. This preliminary action of creating a pre-validated structural platform allows subsequent steering wheel variations to be developed more quickly without requiring full re-validation, as the core structural performance has already been established.
3Shape
If traditional design practice is followed with unique armatures for each style, then each steering wheel can be optimized for its specific appearance, but tooling costs and engineering development costs increase substantially
Solution Approach 1:
The steering wheel is segmented into a standardized structural armature and variable cosmetic finishes. This allows the appearance (shape) to be modified through cosmetic applications rather than structural changes, eliminating the need for unique tooling for each steering wheel style while maintaining design flexibility.
Solution Approach 2:
Different cosmetic finish techniques (injection molding, reaction injection molding, etc.) are applied locally to specific regions of the standardized armature to achieve different steering wheel appearances. This local customization of cosmetic properties allows for styling variations without requiring changes to the underlying structural component or its tooling.
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 reduces tooling and engineering costs, enables faster time-to-market, and maintains consistent performance by allowing styling changes without re-validating the underlying structure, while maintaining the same physical properties.
Implementation Method 1
an external component made of a compressible material including an over-lay providing a complete outer cover for the rim and a complete outer cover for each of the two spokes
Data Source
AI summary
A steering wheel has an internal structural component formed by an armature made of a relatively rigid material such as magnesium or aluminum, or an alloy of magnesium or aluminum, and an external component made of a compressible material such as polyurethane. The armature has a hub, a rim surrounding the hub, and radial spokes extending between the hub and the rim. The external component includes an over-lay providing a rim cover for the rim and a spoke cover for each of the two spokes. The external component also includes one or more parts extending radially inwardly from the rim cover to provide an additional spoke or spokes.