Steering Column Worm Adapter Swedge for Axial Retention
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Solution Overview
Problem
Steering column assemblies with high system output experience high axial loading, necessitating a secondary retention feature for the motor side bearing to prevent axial movement of the worm assembly.
Innovation Solution
A coupler assembly with an adapter that secures the worm member by deforming its end to overlap with the adapter, providing both axial and radial retention, using a swedge tool to compress the worm member and secure it to the adapter, ensuring stable positioning and power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the worm assembly is axially fixed on the outboard side bearing, then radial dampening is achieved, but axial retention on the motor side is insufficient under high axial loading
Solution Approach 1:
The coupling assembly is divided into separate functional components: the adapter provides radial support through bearing mounting, while the swedge provides axial retention through deformation. This segmentation allows each component to specialize in one retention function, improving overall reliability without requiring a single complex retention mechanism.
Solution Approach 2:
The swedge is pre-positioned within the coupling assembly before final assembly. During assembly, the swedge is driven into the adapter, creating preliminary deformation that establishes axial retention. This preliminary action ensures axial retention is built-in during assembly rather than requiring additional adjustment or complex mechanisms.
2Reliability
If a secondary retention feature is added to the motor side bearing, then axial loading is combated, but device complexity increases
Solution Approach 1:
The axial retention function is merged with the coupling assembly structure itself. The swedge, integrated into the adapter, provides axial retention as an inherent feature of the coupling mechanism rather than as a separate secondary retention component. This merging eliminates the need for additional complex retention features while maintaining reliability under axial loading.
Solution Approach 2:
The swedge utilizes material deformation as a retention mechanism. By changing the physical state of the swedge material from undeformed to deformed through compression, axial retention is achieved. This parameter change (deformation) provides a simple yet effective means of resisting axial loading without adding complex mechanical retention features.
3Reliability
If the worm member end is deformed to overlap the adapter, then axial and radial retention is achieved, but manufacturing complexity increases
Solution Approach 1:
The swedge tool serves multiple functions during assembly: it compresses the worm member end, creates the deformation, and establishes the overlap with the adapter all in a single operation. This self-service approach consolidates multiple manufacturing steps into one action, improving ease of manufacture while ensuring reliable retention.
Solution Approach 2:
The deformation tool is designed to pre-form the worm member end into the required shape before final assembly. This preliminary deformation action ensures the worm member end is pre-shaped to overlap the adapter correctly, simplifying the final assembly process and improving manufacturing ease while maintaining reliable retention.
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 effectively retains the worm member in position, preventing axial and radial movement, thereby enhancing the stability and efficiency of power transfer in steering column assemblies, particularly under high axial loading conditions.
Implementation Method 1
pressing a swedge tool against a face of the worm member in a direction substantially parallel with the central axis deforms the first end to overlap a portion of the worm member onto a portion of the adapter
Data Source
AI summary
A steering assembly including a motor assembly, a worm assembly, and a coupler assembly is provided. The worm assembly includes a worm member defining a central axis and having first and second ends. The coupler assembly may include an adapter having a first wall defining a through-hole sized to receive a portion of the first end therein. The coupler assembly may operatively connect the motor assembly and the worm assembly. The worm member and the adapter may be arranged with one another such that pressing a swedge tool against a face of the worm member in a direction substantially parallel with the central axis deforms the first end to overlap a portion of the worm member onto a portion of the adapter adjacent the through-hole to secure the worm member and adapter to one another and to axially retain the worm member in a position relative to the central axis.