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Status

Status
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titleIn Progress

Owner

Gerard Cardenas

Contributors

Philip Bortolotti Cesar Hernandez

Approved

Due date

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

Table of Contents
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❓ Problem statement

There 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

Output Shaft to Coupler

Option 1

Option 2

Option 3

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

Screenshot

Link

Benefits and risks

(plus) Relatively easy to manufacture - no need for welding

(plus) No need for a special shaft (splined shaft or DD shaft)

(minus) Constraining with a bolt going through a through hole can deform the shaft (might have to use steel)

(plus) A stronger alternative to using a bolt to constrain shaft

(minus) Need to use steel to weld onto the coupler

(minus) Coupler steel grade not specified, may be risky to weld

(plus) Opens up the opportunity to use a u joint that has a shaft diameter other than 5/8”

(minus) Coupler steel grade not specified, may be risky to weld

Criteria

U-joint

Option 1

Option 2

Option 3

Overview

Smooth Bore

Spline

DD Shaft

Screenshot

image-20240602-195310.png

image-20240602-195502.png

image-20240602-195556.png

Link

Benefits and risks

(plus) Can accommodate regular smooth pipes - no need for special shaft (spline shaft or D shaft)

(minus) Only way to constrain the shaft is to weld the shaft onto the u joint - shaft needs to be same material as the u joint

(plus) No need to drill extra holes

(minus) May be difficult to find a spline shaft (at least in the desired size)

(minus) Shaft cannot be hollow - adds weight

(plus) No need to drill extra holes

(minus) May be difficult to find a double d shaft (at least in the desired size)

(minus) Shaft cannot be hollow - adds weight

Criteria

✅ Follow up

Decision

Status

Next steps

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💎 Source files

Type /link to add links to design files.