Steering Wheel Safety Module Alignment via Laser-Welded Centering
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Solution Overview
Problem
Existing vehicle steering wheel assembly methods are complex and prone to misadjustments, leading to inconsistent symmetry and clearances between decorative components, which can compromise the robustness and longevity of the assembly.
Innovation Solution
A vehicle steering wheel design featuring a framework, safety module, and decorative components with centering components irreversibly connected via laser welding, allowing for precise adjustment and modular manufacturing of clearances without bulky tools, ensuring robust positioning and reduced tolerance issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional assembly methods with bulky fittings and tools are used, then adjustment capability is provided, but space requirements increase and manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical adjustment systems with bulky fittings and tools with a laser-based positioning and welding system. The laser device enables precise positioning and irreversible connection without requiring complex mechanical adjustment mechanisms, thereby reducing space requirements and manufacturing complexity while maintaining adjustment capability during the positioning phase.
Solution Approach 2:
The patent extracts the adjustment function from complex mechanical assemblies and concentrates it in a simplified laser positioning system. By separating the positioning phase (using laser guidance) from the fixing phase (using laser welding), the system eliminates the need for bulky adjustment mechanisms while preserving the essential adjustment capability during assembly.
2Reliability
If traditional welding methods like ultrasonic welding are used, then irreversible connection is achieved, but vibration and movement requirements increase tolerance constraints
Solution Approach 1:
The patent replaces ultrasonic welding, which requires vibration and relative movement between parts, with laser welding. This substitution eliminates the need for vibration mechanisms and reduces the tolerance constraints on part movement and positioning, as laser welding can accommodate tighter tolerances without requiring dynamic adjustment during the welding process.
Solution Approach 2:
The patent changes the welding parameters from ultrasonic vibration-based processing to laser-based thermal processing. This parameter change fundamentally alters the welding mechanism, eliminating the need for mechanical vibration and reducing the sensitivity to part movement and misalignment, thereby improving positioning accuracy while maintaining manufacturing precision.
3Productivity
If modular manufacturing with distributed welding is implemented, then manufacturing flexibility and adjustment capability improve, but coordination complexity increases
Solution Approach 1:
The patent implements a universal laser welding system that can be deployed at multiple manufacturing locations (base component plant, safety module plant, steering wheel assembly plant). This single technology platform performs the same irreversible connection function across different stages and locations, simplifying coordination compared to using different welding technologies at each stage, while maintaining high manufacturing flexibility.
Solution Approach 2:
The patent enables preliminary irreversible connection of centering components at early manufacturing stages (at the base component or safety module plant) before final assembly. This preliminary action allows for early positioning and fixation, reducing coordination complexity during final assembly while maintaining the flexibility to perform adjustments and modifications at different manufacturing stages.
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
The solution simplifies manufacturing, enhances modularity, and ensures precise positioning of decorative components, improving the perceived quality and durability of the steering wheel by eliminating the need for complex adjustments and minimizing material consumption during welding.
Implementation Method 1
the irreversible connection is provided by laser welding of the centering component on the base component and/or on the safety module
Data Source
AI summary
The invention relates to a vehicle steering wheel, comprising:a framework,a safety module comprising a first decorative component,a base component,at least one centering component, attached and fixed to the base component by an irreversible connection and arranged to position the safety module with respect to the base component,at least one second decorative component mounted on the framework,wherein the irreversible connection is arranged to permit an adjustment of the position of the centering component on the base component before fixing the centering component on the base component,characterized in that the irreversible connection is provided by laser welding of the centering component on the base component.