Steering shaft assembly having anti-pull apart feature

Patent metadata

Field	Value
Publication number	US-2018283442-A1
Application number	US-201715478650-A
Country	US
Kind code	A1
Filing date	Apr 4, 2017
Priority date	Apr 4, 2017
Publication date	Oct 4, 2018
Grant date	—

Abstract

A method of manufacturing a steering shaft assembly includes inserting an inner shaft into an outer shaft along a longitudinal axis. The method further includes placing the inner shaft and the outer shaft into a tool having a staking tool provided with a staking feature; aligning a stake with a base of a tooth of the plurality of fine teeth of the outer shaft; and pressing the stake axially into an outer shaft first end to a predetermined depth using the staking feature.

First claim

1 . A steering shaft assembly, comprising:
an outer shaft having an outer shaft internal surface and an outer shaft external surface extending between an outer shaft first end and an outer shaft second end, the outer shaft internal surface defines an internally splined portion having a plurality of fine teeth that extends from the outer shaft first end towards the outer shaft second end; an inner shaft at least partially received within the outer shaft along a longitudinal axis, the inner shaft having an inner shaft external surface extending between an inner shaft first end and an inner shaft second end; and a stake axially extending into the outer shaft first end and the stake extends across a width of a tooth of the plurality of fine teeth and a space defined between adjacent teeth of the plurality of fine teeth, the stake being spaced apart from the inner shaft as the inner shaft moves relative to the outer shaft and arranged to resist a predetermined axial separation load being applied to the outer shaft and the inner shaft.

2 . The steering shaft assembly of claim 1 , wherein the stake extends a predetermined depth into the outer shaft.

3 . The steering shaft assembly of claim 1 , wherein the stake is provided with a rectangular cross-section.

4 . (canceled)

5 . The steering shaft assembly of claim 1 , wherein the plurality of fine teeth have a tooth height of less than 1 mm.

6 . The steering shaft assembly of claim 1 , wherein the stake extends at least partially through the outer shaft internal surface and extends towards the outer shaft external surface.

7 . A method of manufacturing a steering shaft assembly, comprising:
inserting an inner shaft having an inner shaft external surface at least partially into an outer shaft having an outer shaft internal surface provided with a plurality of fine teeth along a longitudinal axis; placing the inner shaft and the outer shaft into a tool having a staking tool provided with a staking feature; aligning a stake with a base of a tooth of the plurality of fine teeth of the outer shaft; and pressing the stake axially into an outer shaft first end to a predetermined depth using the staking feature.

8 . The method of claim 7 , further comprising:
monitoring a press load applied to the stake; and monitoring a total displacement of the stake relative to the outer shaft.

9 . The method of claim 8 , wherein in response to a press load rate of change greater than a threshold rate of change, ceasing pressing the stake axially.

10 . The method of claim 8 , wherein in response to the press load being at least a threshold press load and the total displacement being less than predetermined depth, outputting a warning for display.

11 . The method of claim 8 , wherein the stake spans across a width of the tooth of the plurality of fine teeth and a space defined between adjacent teeth of the plurality of fine teeth.

12 . A steering shaft assembly including an outer shaft having an outer shaft internal surface provided with a plurality of fine teeth and an inner shaft configured to be inserted into the outer shaft, the steering shaft assembly being assembled by a method comprising the steps of:
placing the outer shaft into a tool having a staking tool provided with a staking feature and a bottoming feature; aligning a stake with an outer shaft first end proximate a base of a tooth of the plurality of fine teeth; and pressing a stake axially into the outer shaft first end to a predetermined depth using the staking feature.

13 . The steering shaft assembly of claim 12 , wherein a width of the stake is equal to a width of the tooth of the plurality of fine teeth and a space defined between adjacent teeth of the plurality of fine teeth.

14 . The steering shaft assembly of claim 12 , wherein each tooth of the plurality of fine teeth has a height of less than 1 mm.

15 . The steering shaft assembly of claim 12 , the method further comprising the step of:
monitoring a plurality of physical parameters related to the pressing of the stake.

16 . The steering shaft assembly of claim 15 , wherein the plurality of physical parameters related to pressing the stake include at least one of a displacement of the stake relative to an outer shaft first end, a press load, engagement of the bottoming feature with the outer shaft first end, and a press load rate of change.

17 . The steering shaft assembly of claim 16 , the method further comprising the step of:
ceasing pressing the stake, in response to at least one of the stake reaching a predetermined depth, engagement between the bottoming feature and the outer shaft first end, the press load being within a predetermined press load range, and the press load rate of change being within a predetermined press load rate of change range.

18 . The steering shaft assembly of claim 16 , the method further comprising the step of:
ceasing pressing the stake and outputting a warning for display, in response to at least one of the stake not reaching a predetermined depth and engagement between the bottoming feature and the outer shaft first end, the press load not being within a predetermined press load range, and the press load rate of change not being within a predetermined press load rate of change range.

Assignees

• Steering Solutions Ip Holding

Inventors

• Brzezinski Gregory D
• Kolhagen Benjamin J
• Nelson Harold J

Classifications

• B23P11/00

  Connecting or disconnecting metal parts or objects by metal-working techniques not otherwise provided for  (connecting sheet metal or metal tubes, rods or profiles B21D39/00; riveting B21J; soldering, unsoldering, welding B23K; hand tools for connecting wire or strip B25B25/00; connecting metal parts by adhesives F16B11/00) · CPC title

• B62D1/16 Primary

  Steering columns · CPC title

• F16D3/06

  specially adapted to allow axial displacement · CPC title

• B62D1/20

  Connecting steering column to steering gear · CPC title

• F16C3/03 Primary

  telescopic (axially displaceable couplings F16D3/06) · CPC title