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Decision | We will use a coupler for the pinion input, two 5/8” OD intermediate and output hollow steel shafts, and steel 5/8-36 X 5/8 smooth bore u joints. The sequence of the assembly is as follows: Steering rack → 5/8”-36 spline coupler → 5/8” OD shaft → set screwed into the spline side of a 5/8”-36 spline u joint → smooth bore side welded onto 5/8” OD intermediate shaft → intermediate shaft welded onto smooth bore side of second 5/8” u joint → spline side of u joint set screwed onto steering wheel input shaft | ||||||
On this page |
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❓ Problem statement
U-Joint setup is required to be past the 45 degrees possible for the current U Joints. Additionally, the U-Joints are two different angles => decreasing the power transmission from the steering to the rackThere are many options for components linking the steering wheel to the rack. This decision matrix is to decide the best option for each component.
💡 Research insights
📊 Solution hypothesis
🌈 Design options
Steering rack NEEDS to be extended to reduce the length of the tie rodsHow are we going to positively lock the steering extender (since the rack has a blind hole)
Bolt the clevis into the steering extender (need to safety wire the bolt onto the clevis) and have the adjustable tie rod with heim joints and jam nuts at both ends
Include linear bearings mounted to the frame tubes for support at both ends and implement steering stop at ends of the extenders (as a step in the shaft) to make contact with linear bearing housings at full turn
Output Shaft to Coupler | Option 1 | Option 2 | Option 3 | |||
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Overview | Use a 5/8” OD shaft with a through hole to fix inside of splined coupler with bolt | Use a 5/8” OD steel shaft, insert shaft into coupler, and weld side of shaft onto edge of the coupler | Use a greater diameter steel shaft and weld edge of the shaft to the edge of the coupler | |||
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U-joint | Option 1 | Option 2 | Option 3 | |
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Overview | Smooth Bore | Spline | DD Shaft | |
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✅ Follow up
Decision | Status | Next steps | ||||||||||||||||
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💎 Source files
Type /link to add links to design files.