STEERING COLUMN ASSE BLY

CLAIM OF BENEFIT OF FltiNG DATE AND PRIORITY

[001| The present application claims the benefit of the filing date of, and priority to, United States Application No. 61/935,421 , fiieci February 4, 2014, which is hereby incorporated by reference in its entirety. The present application is also related to United States Application No. 61/935,419, filed February 4. 2014. which is hereby incorporated by reference in Its entirety.

FIELD

[O02J In general, the present teachings relate to an apparatus and method for inspection of a steering column assembly before installation into a transportation vehicle. More particularly, the present teachings relate to an apparatus and method for non- contact inspection of steering column assembly for an automotive vehicle while the steering column assembly is rotatabiy supported at on or both of its end portions.

BACKGROUND

[0033 In the manufacture of steering coiumn assemblies, there are often a number of subassembiies or components that require assembly with each other. For proper operation, many of the subassemblies or components are adapted for rotation about a longitudinal axis upon installation into a vehicle for which it is intended, it is important in the manufacture of steering column assemblies that individual subassemblies or components are properly attached to one another. This is often achieved by one or more crimping, staking or other plastic deformation operations by which a sleeve, a tube, a disk o some other generally cylindrical and hollow object is connected around a shaft, or some other generally cylindrical component so that the connected parts resist longitudinal separation, resist radial displacement, or both. Though it is possible for an assembly line worker to perform a visual and/or manual inspection for quality assurance, such an inspection leaves open the possibility of some subjectivity from one worker to another, and may lead to potentially inconsistent results.

[0043 There is a need for an automated approach to the inspection of steering column assemblies ("steering column assemblies" as used herein contemplate not only final steering coiumn assemblies adapted for installation into a vehicle, but also subassemblies that are incorporated into final steering column assemblies) before installation of the same into a vehicle. There is a particular need for a non-contact approach to the inspection of steering column assemblies (e.g., joints between components of the assemblies) by which the device that conducts the inspection does so without making contact with the steering coiumn assemblies while being inspected. There is also a need for an approach to steering coiumn assemblies that aiiows for rotation of steering column assemblies, but which avoids contact with components of the steering column assemblies in a manner that would potentially damage the steering column assemblies. There also is a need to manage inventory being manufactured and inspected to help assure that assemblies that fall to meet certain criteria are segregated from those assemblies that do meet such criteria.

[0053 The following U.S. patent documents may be related to the present teachings: Published U.S. Patent Application Mas. 20020101595 and 20130170734; and U.S. Patent Nos. 5,162,659; 5,267,381; 5,426,309, ail of which are incorporated by reference herein for a!! purposes.

SU MARY

[0063 The present teachings make use of a simple, yet elegant, approach to non- contact inspection of a steering coiumn assembiy by which the steering coiumn assembiy is rotatabiy supported at one or both of its end regions, and is rotated about a longitudinal axis so that profile data can be gathered about a feature of interest by an optical detection device and used to assure the presence of the feature of interest and/or to determine if the feature of interest meets certain predefined criteria. As gleaned from the following, the teachings contemplate, generally, an apparatus (and associated method) for inspecting a steering column assembiy, including a motor driven drive sieeve having a longitudinal axis adapted for receiving and engaging a portion of the steering column assembiy, and at least one optical scanning device {which desirably is spaced apart from the steering column assembly under inspection) adapted to optically scan a feature of interest of the steering coiumn assembiy while the shaft of the steering coiumn assembly is rotated for gathering data for identifying one or more deviations from one or more predetermined values for the feature of Interest,

[0071 Irs one aspect, the present teachings pertain generally to an apparatus for inspecting a steering column assembly having a longitudinal axis, a first end, a first end portion extending from the first end aSong the longitudinal axis from the first end (and which may include a telescopic shaft subassembly or a component thereof, such as an outer steering wheel interface shaft tube that has an associated steering wheel interface), a second end, and a second end portion including and/or extending from the second end toward the first end along the longitudinal axis (and which may include a stub shaft). The apparatus includes at least one support structure having a longitudinal axis. A headstock may be mounted (e.g., fixedly or transiatably mounted) on the at feast one support structure and includes at least one motor. The headstock may thus be adapted to translate reiattve to the at least one support structure (e.g., via a linear actuator driven b a suitable motor, such as a servo motor) generally along the longitudinal axis of the at least one support structure. The headstock may be able to translate longitudinally and/or transversely, o along another axis of the at least one support structure, A drive sleeve having a longitudinal axis is supported in the headstock for rotation by the at least one motor. The drive sleeve includes an inner wall surface that is adapted for receiving and engaging the first end portion of the steering column assembly,

[008| An optional taiistock (which may be carried on the support structure or on another support structure) may optionally include a roller pin having a longitudinal axis. The longitudinal axis of the roller pin is substantially juxtaposed with the longitudinal axis of the drive sleeve. The roller pin has an outer surface that is adapted for engaging the second end portion of the steering column assembly and for bearing against the second end portion during rotation of the shaft so that the shaft is suspended relative to the at least one support structure. One or both of the headstock or the taiistock may be transiatably mounted relative to the other for bringing them together or moving them apart from each other.

[0093 At least one optical scanning device (which may be carried by the support structure, its own support structure, or th support structure of the optional taiistock) is also included. The at feast one optical scanning device is adapted to scan for the presence or absence of a feature of interest and/or for a characteristic of a feature (e.g„ a surface feature) of interest of the steering column assembly while the shaft of the steering column assembly is rotated for gathering data, such as for identifying one or more deviations from a predetermined value for the feature of interest. In this regard, it is envisioned that the at least one optical scanning device is adapted to emit a beam and the at least one optical scanning device is oriented so that the beam is aimed at the feature of interest of the steering column assembly. For an apparatus that includes the optional taiistock and rolier i , the apparatus is such that, upon receiving and engaging the first end portion of the shaft of the steering column assembly, the headstock is adapted for actuation to translate it toward the rolie pin so that the roller pin engages the second end portion of the steering column assembly and the steering column assembly is rotated while being scanned by the at least one optica! scanning device,

[0010J The teachings also contemplate a non-contact method of inspecting a steering column assembly. The inspection is performed after manufacture of the steering column assembly and prior to installation into a vehicle. The method may employ steps of engaging a portion (e,g. _f a first end portion) of the steering column assembly with an interior surface of a drive sleeve (e.g., so that line or plane contact is made with a portion of the steering column assembly generally continuously or intermittently about the perimeter of the assembly), While the portion {e.g., first end portion) is engaged with the drive sleeve, it is rotated {e.g., by being driven by a motor) while being scanned by at least one optical scanning device, A step is employed of comparing data obtained by the at least one optical scanning device with one or more known and predetermined values for a reference steering column assembly. For example, the comparing step ma perform a comparison of relative locations of a plurality of features of interest in a steering column assembly under inspection with known values for relative locations of corresponding features obtained from scanning a steering column assembl that has been predetermined to satisfy established quality criteria. Based upon the comparing step, an inspected steering column assembly can either be approved or rejected, and conforming and non-conforming steering column assembiies can be segregated from each other,

[0011| A method of the present teachings contemplates use of the apparatus of the present teachings for non-contact inspection of a steering column assembly that is specifically designed and intended to generally include a worm-wheel at the second end portion, and a sensor sleeve fixed in position between the worm-wheel and the first end. The sensor sleeve may b attached to a shaft with a crimp and/or a dimple that penetrates into a groove of the shaft. Thus, the method includes inspecting steering column assemblies for one o any combination of the following features of interest', dimple location, dimp!e depth, dimple location relative to a groove in the spline shaft portion, sensor sleeve appearance, sensor sleeve runout, sensor sleeve peripheral crim appearance, sensor sleeve crimp angle, distance from a location on the sensor sleeve to a shoulder on the spline shaft portion, location of a c-ring groove, distance of a c-ring groove relative to a surface on the worm- wheel, position of the sensor sleeve relative to a worm-wheel surface, distance from a location o the sensor sleeve to a worm-wheel surface, !ocation of the worm-wheel relative to a predetermined location in the spline shaft portion, or any combination of the foregoing.

[0012} The present teachings provide a number of technical benefits, including but not limited to the ability to consistently and reproducibiy inspect steering column assemblies for assuring that the assemblies meet predefined criteria, the abilit to inspect a variety of different steerin assemblies without the need to modify any hardware of an inspection apparatus, the ability to inspect steering column assembiies before installation into a vehicle (e.g., a location of manufacture or storage), the ability to identify nonconforming steering column assemblies before additional costly assembly steps are performed and to thereby help reduce scrap rates of expensive assemblies, or any combination of the foregoing.

BRIEF DESCRIPTION OF THE DRAWINGS

[00131 F¾- is a perspective view of an illustrative steering column assembl that may be inspected in accordance with the present teachings,

[0014J Fig. 18 is an enlarged side view of a portion of the assembly of Fig. 1 A.

[00153 Fig. 2A is a perspective view of an illustrative apparatus in accordance with the present teachings in a first unloaded position .

[00161 Fig. 2B is a perspective view of an illustrative apparatus in accordance with the present teachings in a second loaded position,

[00173 Fig. 2C is an eniarged partial perspective view of the apparatus of Fig. 2A in a loaded position.

[00183 FiQ- 20 is an enlarged partial side section view of the apparatus of Fig. 2A in a loaded position.

[00193 Fig. 2E is a side view of the apparatus of Fig. 2A.

[00203 Fig- 2F is a top view of the apparatus of Fig. 2A.

[00213 Fig. 2G is a bottom view of the apparatus of Fig, 2A.

[00223 Fig. 2H is an enlarged partial transparent view of an end region of the apparatus of Fig. 2A, to further illustrate the roller pin engaging a steering column: assembly.

[0023J Fig. 2! is a side sectional view of the apparatus of Fig. 2A.

[00243 Fig, 2 J is a side view of an illustrative rolle pin.

[00251 Fi - 3A is a side sectional view of a motor driven roiatable end region support structure and drive sieeve of the apparatus of Fig. 2A. in accordance with one Illustrative example of the present teachings.

[00263 Fig. 3B is a perspective view of the drive sieeve of Fig. 3A.

[00273 F gs. 4A, 4B, 4G and 4D are a series of side sectional views illustrating the versatility of the drive sleeve of Figs. 3A and 3B to accommodate a number of different shafts,

[00283 Figs- 5A, 58, 5C and SD are a series of perspective views corresponding respectively with the views of Figs. 4A-4D.

[00293 Fig. 6A is a depiction of an illustrative system in accordance with the present teachings, including an apparatus contained within a housing.

[00301 ^F i - 6B is a depiction to illustrate data displayed in accordance with the teachings.

[0031J Figs, 7A, 78 and 7C are side sectional views showing how a roller pin is employed for elevating a steering column assembly and suspending it for inspection,

DETAILED DESC IPTOR

[0032J As required, detailed embodiments of the present teachings are disclosed herein; however. It Is to be understood that the disclosed embodiments are merely exemplary of the teachings that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis fo teaching one skilled in the art to variously employ the present invention.

[00333 in general, and as wiii be appreciated from the description that follows, the present teachings pertain to pre-vehicle installation quality inspection of steering column assemblies to assure that the assemblies being inspected have the intended design features and meet the intended design criteria. The steering column assemblies generally are envisioned to have an intended design such that the assemblies have a longitudinal axis and a telescoping shaft assembly. The telescoping shaft assembly has a first end that defines a steering wheel interface. A worm-wheel for interfacing with a power assist device is mounted on a stub shaft (which defines a second end portion and includes a second end of the steering column assembly) that is Joined to the telescoping shaft assembly. The stub shaft may be suitably coupled to an intermediate shaft for actuating a rack and pinion assembly of a vehicle. A sensor sleeve surrounds sensing hardware and is attached (e.g., crimped with a peripheral crimp) to the telescoping shaft assembly. A dimple in the sensor sleeve that penetrates a recess in the telescoping shaft assembly may be employed to aid the sensor sleeve in resisting rotation. As gathered from the above, the present teachings thus pertain generally to an apparatus and method for inspecting a steering column assembly having a Iongitudinai axis, a first end, a first end portion extending from the first end along the longitudinal axis from the first end, a second end, a second end portion including and/or extending from the second end toward the first end along the longitudinal axis. One object of the teachings thus is to help assure that a steering column assembly being Inspected has the intended design features, such as the features described above generally, and more particularly addressed herein.

[0034] As indicated, in one aspect, the present teachings pertain generally to an apparatus that includes at least one support structure having a longitudinal axis. A headstock i mounted {e.g., it may be transiatably mounted) on the at least one support structure and includes at least one work-piece drive motor. The motor may be adapted to rotate a steering column assembly that is loaded in the apparatus about the longitudinal axis of the steering column assembly. The headsiock may include a shroud that contains the motor or a drive mechanism associated with the motor. The shroud may substantially surround the headstock, but may include openings at opposing ends. In that way, the headstock will be able to receive the first end portion of the steering column assembly and will also expose the first end so that the end is abl to be coated with a colorant, dye, or other detectable coating that denotes whether or not the steering column assembly has passed inspection. The shroud may extend around the support structure. The shroud may include one or more guide structures adapted to translate along one or more longitudinally oriented tracks associated with the support structure, such as on the underside of the support structure, in this manner, it may be possible to help direct the travel of the headstock relative to the support structure, The at ieast one work-piece drive motor may be integrated with the headstock. The at ieast one work-piece drive motor may be separate from the head stock (e.g., at remote location). A belt drive may enable the motor to he located in one location (e.g., at or near the center of the at Ieast one support structure), whiie the headstock is located at an end of the at ieast one support structure. The headstock may otherwise be adapted to be driven relative to the at least one support structure (e.g., via a linear actuator driven by a suitable motor, such as a servo motor) generaily along the longitudinal axis of the at least one support structure. The motors for use in accordance with the present teachings may be a servo motor. By way of illustration, motors herein may have the characteristics of a motor available commercially from Omron (e.g., under the number 88M-K0030LS2).

[00353 A drive sieeve having a longitudinal axis is supported in the headstock for rotation by the at ieast one work-piece drive motor. The work-piece drive motor may include an output shaft that has a gear, a roller, or som other drive structure that meshes with or otherwise engages an opposing gear or drive surface that surrounds the drive sleeve. Thus, the work- piece drive motor may rotate for causing a steering column assembly that is supported in the drive sleeve to rotate about the longitudinal axis of the steering column assembly. The work- piece drive motor may rotate for causing a steering column assembly thai is supported in the drive sieeve to rotate about the longitudinal axis of the steering column assembly. For example, the drive sleeve may be surrounded along a portion of its length by a suitable bearing. The drive sieeve may have a suitable gear that generally surrounds the drive sleeve and is driven by a gear associated with the output shaft of the work-piece drive motor or an intermediate idler gear. The drive sieeve gear, an output shaft gear and any idler gear may be adapted to rotate in a common plane and about an axis that is generally parallel with the axis of the steering column assembly being inspected.

[00361 *ive sleeve will include a longitudinal axis that is generally parallel with (or coaxial with) the longitudinal axis of the steering column assembly that it receives, a first end and a second end At the first end, there may be an opening, so that a through passage is defined along the length of the drive sleeve. At the second end there may be a peripheral flange. The drive sleeve will include an inner wall surface thai is adapted for receiving and engaging the first end portion of the steering column assembly. The inner wall surface may include one or a plurality of cylindrical wail segments, one or a plurality of frusio-conicai wa!i segments, or a plurality of arcuate wall segments, o any combination thereof. The inner wall surface desirably will include a plurality of wall segments, each having a cross-sectionai area (taken transverse to the longitudinal axis of the drive sieeve) that progressively reduces in

? size from the second end toward the first end, for at least a portion of the iength of the drive sleeve. One or more shoulders may be defined at the intersection of successive wall segments. As a result of having such inner waif structure, the drive sleeve is able to receive the first end portion of a variety of different steering column assembiies. each having a differently configured and/or differeniiy dimensioned first end portion. The shoulders allow such steering column assembiies to engage the drive sleeve at a location aiong the first end portion. The drive sleeve may have a continuous inner wall surface. The drive sleeve may have an intermittent wail surface. The drive sieeve may include a plurality of jaws that grip the end portion of the steering column assembly.

[00371 The drive sleeve may be made of a softer materia! than the material of the first end portion of the steering column assemblies supported therein, so that during loading and Inspecting, damage to the steering column assembiies Is avoided. The drive sleeve may have a surface texture, may be made of a material having a sufficiently low coefficient of friction, or both, so that when the drive sleeve is rotatab! driven by the work-piece drive motor, the first end portion of the steering column assembly being Inspected remains engaged with the drive sieeve. For example, the drive sleeve may be a polymeric materia! (e.g., an elastomeric material). The drive sleeve may engage the periphery of a tapered portion of the first end portion. For example, it may engage a tapered wall of an outer tube of the steering column assembly {e.g., an outer tube of a telescopic steering column assembly).

[00383 An optional taiistock may be employed (which may be carried on the support structure or on another support structure), which may carry a suitable roller pin, e.g., an idler pin, having a longitudinal axis. The roller pin may be supported for rotation (e.g., by way of a suitable bearing, such as a roller bearing that surrounds the roller pin and is fixed in position in the taiistock). The optional taiistock may be fixed in position on Its support structure, or it may be longitudinally translatable along the apparatus. Thus, the headstock and the taiistock may be translatable relative to each other. The longitudinal axis of the roller pin is substantially juxtaposed with the longitudinal axis of the drive sleeve. The roller pin has an outer surface that is adapted for engaging the second end portion of the steering column assembly and for bearing against the second end of the steering column assembly during rotation of the shaft so thai the shaft is suspended relative to the at least one support structure. The roller pin may include a free end that engages the second end of a steering column assembly being inspected. The roller pin may be dimensioned so that it can penetrate into a recess of the second end of th steering column assembly. For instance, the roller pin may be supported for rotation about its longitudinal axis (e.g., the roller pin may be supportably carried by a suitable bearing associated with the taiistock, such as at least one round bearings supported by a bearing block). The roller pin may have a free end that is rounded or at least partially conical (e.g., it may have a flat portion and a conical portion). It thus may have a tapered wall portion. The tip of the roller pin may have a ball disposed therein,

[00393 work-piece end support platform may be located next to or as part of the tailstock. The work-piece end support platform may be carried by the same support structure as the tailstock. or a different support structure. The work-piece end support platform may have an upper surface that includes a concave depression, a v-shaped depression or some other depression adapted to support a second end portion of a steering column assemb!y when the steering column assembly is initially placed for inspection on the apparatus, The upper surface may be located at a position that is offset relative to the longitudinal axis of the roller pin. The upper surface may be located at a position such that when the second end portion of a steering column assembly is initially placed thereon, and the first end portion becomes engaged by the drive sleeve, the longitudinal axis of the steering column assembly is initially at an angle of about 1 to about 20 ^a , and more preferably about 2 to about 10° relative to the iongitudina! axis of the drive sleeve. For embodiments that include a tailstock as described herein, as the headstock and/or the tailstock are translated relative to each other, the second end of the steering column assembly will contact the roller pin and bear against the roller pin until the roller pin becomes located within the recess of the second end. As a result, the second end will become elevated from the upper surface of the work-piece end support platform.

[0040] At least one optical scanning device (which may be carried by the support structure, it own support structure, or th support structure of the tailstock) is also included. The at least one optical scanning device is adapted to scan a feature (e.g., a surface feature) of interest of the steering column assembly while the shaft of the steering column assembly is rotated for gathering data for identifying one or more deviations from a predetermined value for the feature of interest, in this regard it is envisioned that the at least one optical scanning device is adapted to emit a beam and the at least one optical scanning device is oriented so that the beam is aimed at the feature of interest of the steering column assembly. The apparatus may be such that, upon receiving and engaging the first end portion of the shaft of the steering column assembly, the headstock is adapted for actuation to translate it toward the roller pin so that the roller pin engages the second end portion of the steering column assembly and the steering column assembly is rotated while being scanned by the at least one optical scanning device.

[00413 Th at least one optical scanning device may be a suitable in-line profile measurement device. The at least one optical scanning device may include a light beam emitter (e.g., a laser beam emitter), which may be adapted to emit a generally diffuse beam (e.g., the beam may be emitted so that, at the location where it reflects off a steering column assembly, a linear segment (e.g., a blue linear segment) is visible). For example, it may include a blue laser beam emitter {i.e., it emits blue light at a wavelength of about 360 to about 480 rim (e.g., at about 405 nm)}. The at least one optical scanning device may include a suitable detector positioned relative to the Sight beam emitter for detecting reflection from a surface of the steering column assembly being inspected. The detector may include a solid state detector, such as a complementary metal oxide semiconductor detector. The at least one optical scanning device may include one or more Senses {e.g., at least one cylindrical lens) fo focusing the beam from the emitter source, and/or a two dimensional lens device (e.g., a lens device that may include one or a plurality of lenses that can concentrate light entering it from various angles to a single point, such as an E nostar lens) for receiving at least a portion of the light that Is reflected from the steering column subassembly. The at least one optical scanning device may include a suitable processor adapted to acquire data from the detector and output such data to a suitable display device. The processor (or another processor) may b suitably programmed to perform a comparison of data acquired from inspecting a steering column assembly with predetermined values (e.g., values stored in memory associated with the processor performing the comparison) or other data about a known reference steering column assembly. The processor may be suitably programmed to output the results of an inspection of a steering column assembly. In this regard, the processor may be suitably programmed to cause an audible alarm, a visual aSarm, o both, to issue if a steering column assembly passes or fails an inspection. The processor may be suitably programmed to identify one or more features of interest that fails to meet a predetermined criteria for such featur An example of a commercially available optica! scanning device is Model No. LJ-V7080, available from eyence Corporation of America. The scanning device may include and/or be ab!e to detect other sources, such as electromagnetic radiation, sound, or other types of waves, instead of or in addition to light,

[00423 Optionally, the apparatus of the present teachings may also include an intermediate work-piece support platform. The intermediate work-piece support platform may include a support surface that can be actuated to raise or lower a steering column assembly placed thereon. For example, the intermediate work-piece support platform may be adapted to be raised or lowered {e.g. , pneumatically, via one or more air cylinders that support an upper surface, by an electric motor, or otherwise). The intermediate work- iece support platform may have an upper surface thai includes a concave depression, a v-shaped depression or some other depression adapted to support an intermediate portion of the steering column assembly (e.g., between the first and second ends) so that the first end of the steering column assembly can be brought in generall opposing relationship with the drive sleeve (e.g., their respective longitudinal axes are generally aligned). For example, the intermediate work-piece support platform may receive a steering column assembly at a first height. It may then be actuated to raise the steering column assembly to a second height so that the longitudinal axis of the steering column assembly is generally opposite the longitudinal axis of the drive sleeve. Thereafter, upon engagement of the first end of the steering column assembly with the drive sleeve, the intermediate work-piece support platform is lowered so thai it no longer supports the steering column assembly.

[00431 T e apparatus of the present teachings optionally ma also include a suitable marking device adapted for marking a visual indicator onto a surface of a steering column assembly that has been inspected based upon the results of the inspection. Fo example, if a steering column assembly fails an inspection the marking device may be actuated to mark the steering column assembly. Alternatively, if a steering column assembly passes an inspection the marking device may be actuated to mark the steering column assembly. The marking device may include a coating spray device that includes a spray nozzle that is in fluid communication with a source of a liquid coating (e.g., a dye. a colorant, or some other coating) aimed toward a steering column assembly whiie the steering column assembly is positioned on the apparatus of the present teachings. For example, a suitable bracket may be mounted to the deadstock for carrying the spray nozzle in opposing relation to an open first end of the drive sleeve

[00443 The apparatus may also be part of an assembly that includes a housing. The housing may be a substantially enclosed housing. The apparatus, the housing, or both, may have an associated display device for providing an operator with visual results from an inspection. There may be one or more suitable input devices for allowing an operator to control operation of the machine. There may be one or more bins for collection of steering assemblies that pass or fail inspection. There may be one or more load ceils associated with the collection bins apparatus that is in electronic signaling communication with a processor that identifies if a steering column assembly passes or fails an inspection. In this manner the load eel can assure that a steering column assembly that passes or fails an inspection is placed in the proper coiiection bin. There may be other suitable hardware to assure that an operator has properly segregated inspected steering column assemblies to separate the failed from the passed assemblies. The apparatus may include a device that optically analyzes whether a coating has been applied to a steering column assembly.

[G04S3 As can be appreciated from the above, use of the apparatus of the present teachings may include the genera! step of supportingty locating a steering column assembly on the apparatus so that the first end portion of the steering column assembly can become engaged by the drive sleeve. A step may include advancing the drive sleeve (e.g., by driving the headstock) toward the first end portion of the steering column assembly until the first end portion of the steering column assembly becomes engaged by the drive sleeve. Optionally, the drive sleeve is advanced (e.g., via longitudinally translating the headstock} until any telescopic extension of the steering coiumn assembly that may exist is eliminated. The drive sleeve also may be advanced {e.g., via longitudinally translating the neadsiock} so that the second end of the steering column assembly contacts th roller pin of the taiistock. Upon contacting the roller pin there may be a step of elevating the second end by bearing against the second end until the roller pin becomes engaged in a recess formed in the second end of the steering column assembly. Thereafter, a step of rotating the steering coiumn assembly about its longitudinai axis may b performed, such as by rotatab!y driving the drive sleeve about its longitudinal axis, Whi!e the steering coiumn assembly is rotated about its longitudinal axis, a surface feature of interest is optically analyzed. For example, a step of optically scanning a feature of interest (e.g. , a surface feature of interest) may be performed. The optical scanning may be to analyze a feature of interest selected from dimple location, dimple depth, dimple location relative to a groove in the spline shaft portion, sensor sleeve appearance, sensor sleeve runout, sensor sleeve peripheral crimp appearance, sensor sleeve crimp angle, distance from a location on the sensor sleeve to a shoulder on the spline shaft portion, location of a e-ring groove, distance of a c~ring groove relative to a surface on the worm-wheel, position of the sensor sleeve relative to a worm-wheel surface, distance from a location on the sensor sleeve to a worm-wheei surface, location of the worm-wheel relative to a predetermined location in the spline shaft portion, or any combination of the foregoing.

[00461 A step may be performed of comparing data obtained from the scanning with a known reference value. For example, a step may be performed of scanning a steering coiumn assembly that satisfies predetermined desired quality criteria. Data obtained from such scanning may be stored and used in the comparing step. One approach to the comparing step involves comparing relative positions of surface features of interes with predetermined values for relative positions, without regard to measurements of dimensions. Based upon the results of the inspecting, there may be one or more steps of segregating steering column assemblies that pass inspection from those that fail inspection. The segregating may include locating one or more steering column assemblies in a collection bin. There may be one or more steps of applying a coating onto a steering column assembly that passes or fails an inspection. There may b one or more steps of analyzing (e.g., optically) whether a steering column assembly has a coating applied thereto prior to installation of the steering column assembly in a vehicle,

[0047J The teachings herein are described by reference to a particular illustrative steering column assembly, in general, such an illustrative steering coiumn assembly may have a longitudinai axis, a first end adapted to be attached to a steering wheel, a first end portion adjoining the first end and extending partially along the longitudinal axis, a second end (which may have a recess formed therein, a projection extending therefrom, or both) and a second end portion. At the first end portion there may be at least one telescopic shaft subassembly, such as an outer steering wheel interface shaft tube that has a steering wheel interface (at the first end of the steering column assembly) and that may have a suitable tube in tube surface arrangement. St may have two or more tubes having generally smooth opposing surfaces s!idabie relative to each other. For example, it may have a tube in tube arrangement by which a plurality of longitudinal extending ribs on an inner wall of an outer tube siidingly engage an inner splined shaft having an outer longitudinal spline surface. Mounted to the second end portion may be a worm-wheel having a forward and a rearward face. The second end portion may include a worm-wheel stub shaft, which ma include one or more grooves adapted to receive a snap ring . The stub shaft may be coupled at one end with an intermediate shaft (which, in turn may be coupled with a steering rack and pinion assembly) by way of a suitable coupling. The stub shaft ma be coupled from Its opposing end with the inner shaft {e.g., the inner spiine shaft). For example, the stub shaft may be coupled by way of a torsion bar that is mounted at one of its ends generally within an end portion of the inner shaft {e.g., the inner splined shaft) and is mounted at its other end the stub shaft,

[00483 Adjoining the worm-wheel, and being carried on the inner shaft (e.g., the Inner spiined shaft), there ma be a suitable sensor sleeve. The sensor sleeve may be part of a sensor assembly adapted for defecting torque (e.g., by impedance detection, by inductance detection (such as is taught in United States Patent No. 7,814,803, incorporated by reference), by magnetic detection (such as is taught in United States Patent No. 8,102,138, incorporated by reference), or otherwise) of the worm-wheel stub shaft relative to the inner shaft {e.g., the inner spiined shaft), in this manner, it may b possible to detect when one or more predetermined torsional conditions are satisfied for causing a power assist device {e.g., a power assist motor) to supply additional force to the worm-wheel stub shaft for assisting a vehicle operator complete a steering operation. For instance, the sensor sleeve may include a first end and a second end, such that the second end substantially adjoins a shoulder formed on the rearward face of the worm-wheel. The sensor sleeve may inciude a plurality of windows circumferentiaily disposed about the sleeve. The sensor sleeve may generally surround one or more bodies associated with the stub shaft in a sensing relationship, so that when there is torsional movement of the inner shaft (e.g., the inner spiined shaft) causing the sleeve to rotate relative to the one or more bodies, and there is not a corresponding torsional response by the worm wheel stub shaft, the torque generated by the inner shaft (e.g., the inner spiined shaft) is detected and the power assist device is actuated.

[0049] To heip assure proper alignment of components for operation of the sensor assembly, the first end of the sensor sleeve may inciude a suitable cnmp for maintaining its portion on the inner shaft (e.g. the inner spline shaft). For example, it ma have a peripheral crimp that extends substantially the entirety of the periphery of the first end of the sleeve and engages an outer surface of the inner shaft (e.g., the inner spline shaft), so that the sleeve resists longitudinal movement relative to the inner shaft (e.g., the inner spline shaft). The crimp may have an angle {<¾, see Fig. 1B) relative to the longitudinal axis. For example, the crimp may have an angle that ranges from about 10 to about 30°, such as about 14 to about 22°. The sensor sleeve may also be secured relative to the inner shaft (e.g., the inner spiine shaft) with a dimple or other plastic deformity in order to help resist torsional movement of the sensor s!eeve relative to th inner shaft (e.g., the inner spline shaft), The dimple or other deformity may have a depth relative to an outer surface of the sleeve. For example, the dimple may have a depth ranging from about 0.2 mm to about 0.8 mm (e.g., about 0.4 to about 0.8 mm}. The dimple may penetrate into an opposing recess (e.g., a longitudinal groove) formed on the inner shaft (e.g., the inner sp!ined shaft).

[0050] As will be appreciated, other components may form part of the steering column assembly, such as a gear box, an electric power assist motor, a worm-wheel housing unit, one or mor control units, one or more vehicle attachment brackets, one or more bearings, etc. An example of an assembly that may be made in accordance with the present teachings is provided, without limitation, in United States Patent No. 8,102.138, incorporated by reference for ail purposes.

[00511 in accordance with the teachings herein, it is envisioned that an apparatus of the present teachings will be employed in one or more steps of inspecting the crimp (e.g., for location, for peripheral continuity, for angle, or any combination thereof), inspecting the dimple (e.g., for location, depth or, or both), inspecting the worm-wheel position relative to one or more other components of the steering column assembly, inspecting the sensor sleeve for any surface defect, inspecting the relative position of a face of the worm-wheel and a back shoulder on an inner shaft (e.g., the inner splined shaft) of the steering column assembly, inspecting an interface between the worm-wheel and a worm-wheel stub shaft of the steering column assembly {e.g., to help assure rotational imbalance is avoided), or any combination thereof, it should be recognized, however, that the teachings are not intended to be limited to such assembly . The use of the apparatus and method herein is contemplated for othe steering column assemblies as well.

[0052) As will also be seen, though the teachings herein are illustrated by reference to a particular illustrative steering column assembly having a first steering wheel interface, the components of the apparatus of the present teachings make it suitable for essentially universal application over a range of different steering colum assemblies, each having a different steering wheel interface. For example, the teachings make it possible to employ the apparatus for various steering wheel interfaces that may differ relative to each other in length, diameter, tube and/or shaft geometry, or otherwise,

[0053] In general, the teachings herein envision a method of non-contact inspection of a steering column assembly. The method may include a step of engaging a first end portion of the steering column assembly in a drive sleeve. The method may employ a step of translating the steering coiumn assembly so that the second end of the assembly bears against a roller pin and is brought into axiai alignment with the longitudinal axis of the roller pin, which step may include elevating or otherwise transversely translating the second end of the steering column assembly from a first position to a second position. The method may include a step of elevating or otherwise transversely translating the steering column assembly from a first position to a second position at a location that is intermediate the first end and the second end of the assembly. The method may include a step of rotating the steering colum assembly whiie scanning the assembly,

[0054} During the rotating step, data may be obtained continuously about the periphery of a region of interest, data may be obtained intermittently about the periphery of the region of interest, or both. For example, a plurality of scans may be made {e.g., 5 or more, 10 or more, 20 or more, 30 or more, 40 or more, 360 or less, 180 or less, 90 or less, or otherwise) at predetermined intervals for each revolution of the steering coiumn assembly about its longitudinal axis. One or a plurality of revolutions may be made about the longitudinal axis for performing an inspection.

[OOSSJ Such a step may include gathering data about a feature of interest from the scan and comparing such data with predetermined reference data. For example, predetermined reference data may be obtained by scanning a part having features of interest known to satisfy predetermined quality criteria. Such data may be stored in memory and recalled for use when performing a comparing step. It is possible that the reference data will include: relative positions of two or more surface features, one or more dimensions associated with one or more surface features, a surface topography for one o more surface features, or any combination thereof, i one approach it is envisioned that the comparing step compares only relative positions of two or more surface features as between those of a known reference part and those of an assembly being inspected. That is, a quaiitative comparison is made of the surface features without regard to any quantitative data about the feature. There may be a step of applying an optically detectable coating (e.g.. a paint, a dye, or otherwise) to a steering coiumn assem ly to denote whether o not the assembly has passed an inspection,

[00561 The method may include a step of issuing an alarm signal {e.g., an audible and/or visual signal) if a steering coiumn assembly being inspected fails to meet certain criteria, or alternatively, issuing an alarm signal (e.g., an audible and/or visual signal) if a steering coiumn meets certain criteria. For example, there may be a step of optica!iy analyzing (e.g., using an automated optical scanning device) if an optically detectable coating has been applied, and thereafter issuing an alarm signal based upon the result of the step of optically analyzing,

[0OS?3 Based upon the presence or absence of an afarm signal an operator may pSace a steering column assembly into a collection bin. For example, there may be a collection bin for a steering column assembly that passes an inspection, a collection bin for a steering column assembly that fails an inspection, or both. There may be a step of sensing (e.g., using a load sensor, a motion sensor, or otherwise) whether an operator has placed a steering column assembly into a collection bin as directed.

[00683 One or more other steps may be employed, such as for controlling operation of the apparatus of the present teachings. For example, there may be one or more security steps employed to assure only authorized operators use the apparatus. For example, there may be a step of detecting data about an operator s fingerprint and comparing it against data about fingerprints of authorized operators stored in memory.

[00§9j Referring now to Figs. 1A, 1 B, 4A, 4D, 5A and 50, there is seen an illustrative steering column assembly 10 for which an inspection can be performed in accordance with the present teachings. In genera!, th assembly 10 has a longitudinal axis (LA), a first end 12 adapted to be attached to a steering wheel (not shown), a first end portion 14 adjoining the first end and extending partially along the longitudinal axis, a second end 16 and a second end portion 18. At the first end portion 14 there may be at least one telescopic shaft subassembly 20, such as an outer steering wheel interface shaft tube 22 that has an associated steering wheel interface 24 and that has a plurality of longitudinal extending ribs on an inner wall that siidingSy engage an inner shaft 26 (shown as an inner splined shaft having an outer longitudinal spline surface portion 28 and a forward end portion 30). Mounted to the second end portion 8 may be a worm-wheel 32 having a forward face 34 and a rearward face 36, The second end portion includes a worm-wheel stub shaft 38, which may include one o more grooves 40 adapted to receive snap ring. The stub shaft 38 may be coupled proximate a stub shaft forward end portion 42 with an intermediate shaft by way of a suitable coupling (not shown). The stub shaft 38 may be coupled from its opposing end 44 (shown in Fig. 4A) with the inner splined shaft (e.g., by way of a torsion bar 48, as depicted in Fig. 4A) that is mounted at one of its ends generally within the forward end portion of the inner shaft 26 and is mounted at its other end to the stub shaft.

[0060J Adjoining the worm-wheel 32, and being carried on the inner shaft 28, there Is a suitable sensor sleeve 48. The sensor sleeve 48 has a first end 50 and a second end 52, such that the second end 52 substantially adjoins a shoulder 54 (shown in Figs. 4A and SA) formed on the stub shaft proximate the worm-wheel 32. The sensor sleeve 48 has a plurality of windows 56 eireumferentiaily disposed about the sleeve. At the first end 50 of the sensor sleeve there is a crimp 58. The crimp may have an angle ¾. The crim may have a width I,. A dimple 60 is formed in the sensor sleeve as e!l, which penetrates into a groove 62 of the inner shaft 26. The sensor sleeve may generally surround on or more bodies (not shown) associated with the stu shaft in a sensing relationship, so that when there is torsional movement of the inner shaft causing the sleeve to rotate relative to the one or more bodies, and there is not a corresponding torsional response by the worm-wheel stub shaft, the torque generated by the inner splined shaft is detected and the power assist device is actuated.

[0061] At the second end 16 of the steering coiumn assembl there may be a recess 64, which desirably is located in the center of the second end.

[00621 The teachings herein envision inspection of one or any combination of the features of the crimp 58, the dimple 60, the groove 62, the relative positions of one or more of the features of the assembly 10. Without {imitation, for example, the scanning can be performed to analyze dimple location, dimple depth, dimple location relative to a groove in the spiine shaft portion, sensor sleeve appearance, sensor sieeve runout, sensor sleeve peripheral crimp appearance, sensor sleeve crimp angle, distance from a location on the sensor sleeve to a shoulder on the spline shaft portion, location of a c-ring groove, distance of a c-ring groove relative io a surface on the worm-wheel, position of the sensor sleeve relative to a worm-wheel surface, distance from a location on the sensor sleeve to a worm-wheel surface, location of the worm-wheel relative to a predetermined location in the spiine shaft portion, or any combination of the foregoing.

[00633 With reference to Figs. 2A-2G, there is seen how an illustrative steering column assembly, such as the assembly 10, is inspected using an apparaius 110 of the present teachings.

[0064J The apparatus 110 includes at least one support structure 112 having a longitudinal axis (LA2). A headstock 114 is trans!atably mounted on the at least one support structure 112 and includes at least one work-piece drive motor 1 14a. The motor is adapted to rotate a steering coiumn assembly that is loaded in the apparatus about the longitudinal axis of the steering coiumn assembly. The headstock 114 includes a shroud 116. The shroud may substantially surround the headstock 114, but may include openings 18 at opposing ends, in that way, the headstock will be able to receive the first end portion 14 of the steering coiumn assembly 10 and wiii also expose the first end so that the end is abie to be coated with a colorant, dye or other detectable coating that denotes whether or not the steering coiumn assembly 10 has passed inspection. The shroud is configured to include guide structures 120 adapted to translate along one or more longitudinally oriented tracks 122 on the underside of the support structure. The headstock may otherwise be adapted to be driven relativ to the at least one support structure via a linear actuator 124 driven by a suitable motor 126, which may be mounted on the underside of the support structure 112.

1? [00651 A drive sieeve 12S having a longitudinal axis (LA3) is supported in the eadstock 1 14 for rotation by the work-piece drive motor 1 14a. The work -piece drive motor 114a is illustrated as including an output drive mechanism (e.g. , a shaft that supports a gear or a roiier) 118a that operatively engages an opposing drive mechanism 116b (e.g., a gear or a roller) that surrounds the drive sieeve 128 (which may itseif be supported by a suitable bearing). Thus, the work-piece drive motor may rotate for causing a steering column assembly that is supported in the drive sieeve to rotate about the longitudinal axis of the steering column assembly. For example, the drive sieeve may be surrounded along a portion of its length by a suitable bearing. The drive sleeve may have a suitable gear 126a that generally surrounds the sleeve and is driven by a gear associated with the output shaft of the work -piece drive motor or an intermediate idler gear 116b.

[00661 The drive sleeve longitudinal axis is generally parallel with (or coaxial with) the longitudinal axis of the steering column assembly that it receives, a first end and a second end. As seen in Fig. 3A, at the first end of the drive sieeve 12S, there is an opening 130, so that a through passage is defined along the length of the drive sieeve. At the second end 132 ther is a peripheral flange 134. The drive sleeve has an inner wail surface that is adapted for receiving and engaging the first end portion of the steering column assembly. The inner wail surface Is illustrated to include cylindrical wall segments 136, and frusto- conicai wai! segments 138. The segments progressively reduce in size from the second end toward the first end, for at least a portion of the length of the drive sieeve. One or more shoulders 140 may be defined at th intersection of successive wail segments. As a result of having such inner wail structure, the drive sieeve is able to receive the first end portion of a variety of different steering column assemblies, each having a differentiy configured and/or differentiy dimensioned first end portion. This is seen, by way of example, in the drawings of Figs. 4A-4D and 5A-5D, discussed herein. The shoulders allow such steering colum assemblies to engage the drive sleeve at a location along the first end portion. For example, a shoulder may engage a tapered wall of an oute tube of th steering column assembly (e.g., an outer tube of a telescopic steering colum assembly),

[0067] A taiisiock 142 (which may be carried on the support structure or on another support structure) carries a suitable roller pin 144, e.g., an idler pin, having a longitudinal axis (LA4). The longitudinal axis of the roller pin is substantially juxtaposed with the longitudinal axis (LA3) of the drive sleeve. The roiier pin has an outer surface that is adapted for engaging the second end portion of the steering column assembly and for bearing against the second end of the steering column assembly during rotation of the shaft so that the shaft is suspended relative to the at least one support structure. The roiier pin may include a free end portion 146 that engages the second end of a steering column assembly being inspected,

[00681 As seen in Figs. 2H, 2J, and Figs. 7A-7C, the free end 146 of the roller pin may be dimensioned and/or shaped so that it can penetrate into the recess 64 at the second end 18 of the steering column assembly. For instance, the free end 146 may have a rounded tip (as illustrated in Figs, 7A-7C} or a conical tip 148 and a tapered portion 150 that is disposed on a supported rod portion 52 {which may have a threaded portion for attachment to a bearing component). The supported rod, the tip 14S or both may be adapted for rotation. For instance, it may be rotatabiy supported by a suitable bearing assembly 153 {which is depicted to include a round bearing supported by a bearing block) associated with the taiistock 142. The roller pin thus may remain in a fixed longitudinal position, but may be adapted for rotation about a longitudinal axis,

[00691 A work-piece end upport platform 154 is shown as located next to the taiistock 142. The work-piece end support platform 154 is fixed at a predetermined height, relative to the support structure 12 so that at least a portion of the end of the stub shaft that is disposed thereon is generall juxtaposed with the free end 146 of the roller pin. The work-piece end support platform 154 has an upper surface 156 adapted to support the second end portion of a steering column assembl when the steering column assembly is initially placed fo inspection on the apparatus.

[00701 With reference more particularly to Figs, 7A-7C, the upper surface 158 is located at a position that is offset relative to the longitudinal axis of the roller pin. The upper surface may be located at a position such that when the second end portion of a steering column assembl is initially placed thereon, and the first end portion becomes engaged by the drive sleeve, the longitudinal axis of the steering column assembly is initially at an angle (¾ see Fig, 7A)_ As discussed, the angle (a-i) may be about 1 to about 20", and more preferably about 2 to about 10 ^* relative to the longitudinal axis of the drive sleeve. As seen from Figs. A-7C, as the headstoek is translated toward the taiistock, the second end of the steering column assembly will contact the roller pin and bear against the roller pin 144 until the roller pin becomes located within the recess 64 of the second end 16. As a result, the second end will become elevated from the upper surface of the work-piece end support platform.

[0071 J With reference again to Figs. 2A-2C and 2D-2G, there are depicted a plurality of optical scanning devices, namely first second, and third optical scanning devices 180a, 160b and 160c (in this example, there are three optical devices). In this illustration, the optical scanning devices are each supported in spaced relation from the support structure 112 (by one or more bracket structures 162). The optica! scanning devices are positioned so that its emitted beam is aimed at various regions of interest of the supported steering column assembly, and reflection of the beam is able to be detected by a detector associated with the beam emitter, in the example shown in Figs. 2A-2G, the first optical scanning devic 160a is positioned so that its emitted beam is aimed generally at the region proximate the toward face of the worm-wheel, so that the worm wheel position relative to the stub shaft can be inspected and analyzed. The second optica! scanning device 160b is positioned so that its emitted beam is aimed generaliy at the region proximate the sensor sleeve so that the crimp 58, the dimple 60, the groove 82 or any combination thereof can be inspected and analyzed. The third optical scanning device 160c is positioned so that its emitted beam is aimed generaliy at a shoulder 26a on the shaft 26, the end 50 of the sleeve 48, or both (see Fig. 1A), so that (for instance) the relative position of the sleeve 48 and shoulder 26a can be inspected and analyzed.

[0072} In the illustrated embodiment, the apparatus 110 also includes an intermediate work- piece support platform 164. The intermediate work-piece support platform 164 includes a support surface 166, which has a generally v-shaped depression that can be actuated to raise o lower a steering column assembly placed thereon. In this manner, a steering column assembly can be positioned on the support surface and raised or lowered (e.g., via one or more air cylinders 167 (see Fig. 2!)) to be brought in generally opposing relationship with the drive sleeve (e.g., their respective longitudinal axes are generaliy aligned). After engagement by the drive sleeve, with the first end portion of the steering column assembly, the intermediate work-piece support platform 164 can be lowered so that it no longer supports the steering column assembly 10.

[00733 The illustrative apparatus 110 of Figs. 2A-2G is depicted to include an optional marking device 168 adapted for marking a visual indicator onto a surface of a steering column assembly that has been inspected based upon the resuits of the inspection. The marking device 168 has a spray nozzle 1 0 that is in fluid communication with a source of a liquid coating {e.g., a dye. a colorant, or some other coating) aimed toward a steering column assembly while the steering column assembly is positioned on the apparatus of the present teachings, in the embodiment shown, a bracket 172 is mounted to the headstock 114 for carrying the spray nozzle 170 in opposing relation to the opening 130 in the drive sleeve (see Fig. 3A).

[00743 With reference to Fig. 6A, there is depicted how the apparatus 110 ma also be part of an assembly 186 that includes a housing 174 with an associated display device 1 6a for providing an operator with visual resuits from an inspection. One or more suitable input devices 176b {e.g. , switches) for allowing an operator to control operation of the machine are shown. A bin 178 for collection of one or more steering assemblies that pass or fail inspection may be within the housing, or proximate the housing and exterior of the housing. There may be one or more load cells 180 associated with a collection bin. There may also be a suitable optical detector 182 (inside or outside of the housing) for analyzing whether a coating has been applied to a steering column assembly. One or more data output displays 184 may provide visual output that indicates whether a steering column assembly that has been inspected has passed or failed and/or what parameters have or have not been satisfied by the inspected assembly. Fig. 6B illustrates an example of iiiustrative data that may be output via one or more data output displays 184. In that illustration, measure distances between certain surface features are provided as well as caulk (i.e.. crimp) ang!e. For the D4 _t it is shown as highlighted due to an abnormal deviation from the reference distance for the runout of the sensor sleeve relative to the shoulder 26a. Other distances are shown as meeting acceptable tolerances. With reference to Fig, 1A, the measured distances D1 (worm-wheel face to shoulder 28a). D2 (C-ring groove 40 to worm-wheel face), D3 (sensor sleeve to shoulder 28a) and D4 {runout of sensor sleeve along shaft 26) are shown .

[00753 As discussed previously, the teachings herein envision scanning to assure that a steering column assembly being inspected meets certain predetermined criteria. Without limitation, for example, the scanning can be performed to analyze dimple location, dimple depth, dimple location relative to a groove in the spline shaft portion, sensor sieeve appearance, sensor sleeve runout, sensor sieeve peripheral crimp appearance, sensor sieeve crimp angle, distance from a location on the sensor sleeve to a shoulder on the spline shaft portion, location of a c-ring groove, distance of a c-ring groove relative to a surface on the worm-wheei, position of the sensor sieeve relative to a worm-wheel surface, distance from a location on the sensor sieeve to a worm-wheel surface, location of the worm-wheel relative to a predetermined location in the spline shaft portion, or any combination of the foregoing.

[00761 in regards to the operation of the illustrated embodiment, as can be appreciated, upon being placed on the intermediate work-piece support platform 164, the steering column assembly 10 is caused to be raised or lowered while on the platform so that the first end is generally aligned with the drive sieeve 128. The headstock 114 is actuated to translate the drive sieeve so that the drive sieeve engages the first end portion 14 of the steering column assembly, and to cause the second end 16 of the steering column assembly to bear against the roller pin 144, and elevate the second end portion 18 from the work-piece end support platform 154. The intermediate work-piece support platform may then be retracted as well so that the steering column assembly is suspended by the driv sleeve 128 and the roller pin,

[00773 The work-piece drive motor 114a causes the drive sleeve to rotate about its longitudinal axis, while the optical scanning devices 160a, 160b and 160c scan the regions of the steering column assembly to which they are aimed, and obtain surface feature data for the regions. Surface feature data obtained by the optical scanning devices is compared against reference data for determining whether the surface features of interest satisfy predetermined criteria.

[0078J As with any of the embodiments herein, data may be obtained continuously about the periphery of a region of interest. Data may be obtained intermittently about the periphery of the region of interest. For example, a plurality of scans may be made (e.g., 5 o more, 10 or more, 20 or more, 30 or more, 40 or more, 360 or less, 180 or less, 90 or less, or otherwise) at predetermined intervals for each revolution of the steering column assembly about its longitudinal axis,

[00793 As can be appreciated from the above, use of the illustrated apparatus 110 of the present teaching may include the genera! steps of supportingly locating a steering column assembl 10 as depicted in Fig. 1A on the apparatus 110 so that ihe first end portion 14 of the steering column assembly 10 can become engaged by the drive sleeve 128. A step may be employed of advancing the drive sleeve 128 (e.g., by driving the headsiocfc 114) toward the first end portion 14 of the steering coiumn assembly 10 until the first end portion 14 of the steering column assembly 10 becomes engaged about its periphery by the drive sleeve (e.g., at a shoulder 140 of the drive sleeve). The first end 12 of the steering column assembly may penetrate through the opening 130 of the drive sleeve or ma be exposed through the opening 130. A step may be employed of advancing the drive sleeve 128 (e.g., via longitudinally trans!ating the headstock and its associated shroud) so that the second end 16 of the steering column assembly 10 contacts the tip 148 of the free end 148 of the roller pin 1 4. Upon contacting the rosier pin there may be a step of elevating the second end by bearing against the second end 16 until the roller pin 144 becomes engaged in the recess 64 formed in the second end 16 of the steering column assembly 10, Thereafter, a step of rotating the steering column assembly 10 about its longitudinal axis may be performed, such as by roiafabiy driving the drive sleeve 128 about its longitudinal axis. While the steering column assembly is rotated about its longitudinal axis, a surface feature of interest is opticaiiy analyzed. For example, a step of optically scanning a surface feature of interest (e.g., the dimpie 80, the relationship of the dimple 60 to the inner shaft groove 62, the crimp location, the crimp 58 angle, the relative position of the sensor sieeve 48 relative to a feature of the steering column assembly (e.g., relative to the stub shaft shoulder 54), surface topography of the sensor sleeve 48, the interface between the worm-wheel 32 and the shaft on which it is mounted, the relative position of the worm-wheel and a surface feature of interest, or other surface profile, or any combination thereof), may be performed, A step may be performed of comparing data obtained from the scanning with a known reference va!ue. For example, a step may be performed of scanning a steering column assembly that satisfies predetermined desired quality criteria. Data obtained from such scanning ma be stored and used in ihe comparing step. One approach to the comparing step involves comparing relative positions of surface features of interest with predetermined values for relative positions, without regard to measurements of dimensions. Based upon the results of the inspecting, there may be one or more steps of segregating steering column assemblies that pass inspection from those that fail inspection. The segregating may include locating one or more steering coiumn assemblies in a collection bin. There may be one or more steps of applying a coating onto a steering column assembly that passes or fails an inspection. For example, the spray nozzle 170 may dispense a coating of a dye or other detectable coating onto the first end of the steering column assembly that is exposed within the opening 130. There may be one or more steps of analyzing (e.g., optically! whether a steering column assembly has a coating applied thereto prior to Installation of the steering column assembly in a vehicle. For instance, a step of scanning the steering column assembly may be performed using the optical detector 182. Based upon the scanning step, a step of indicating whether the coating is applied may be employed. For instance the readout device 1S4 may display a result and/or display an instruction to the operator. By way of illustration, without limitation, the readout display may issue a read-out that instructs an operator to load a faulty steering column assembly into the collection bin 178. A step of sensing whether the steering column assembly has been loaded in the bin may be performed, such as by the load cell 180, if the steering wheel assembly has not been loaded, the apparatus may temporarily cease operation until such loading has occurred. There may also be a step of assuring that steering column assemblies loaded into the bin are not removed except by predetermined operators, such as an operator that has entered a suitable security code, or has satisfied some other security criteria.

[00801 As seen from the above, the general teachings herein find suitable application for the inspection of one or more stakes, crimps, dimples, or other plastic deformity for joining a tube in tube, and/or a shaft in tube structure.

[0081] While exemplary embodiments are described above, it is not intended that these embodiments describe ail possible forms of the invention. Rather, the words used in the specification are words of description rather than f imitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form furthe embodiments of the invention.

[00823 As can be appreciated, variations in the above teachings may be employed. For example, it may b possible to employ one or more motors for rotating the steering column assembly at or near its second end and/or at some intermediate location.

[00831 A y numerical values recited herein include all values from the lower value to the upper vaiue in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component o a vaiue of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 88, 43 to 51 , 30 to 32 etc. are expressly enumerated in this specification. For values which are less tha one, one unit is considered to be 0.0001 , 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and a!i possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner,

[00843 Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30 ^s is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0085} The disclosures of all articles and references, including patent applications and publications, are incorporated by referenc for ail purposes. The term "consisting essentially of to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of, or even consisting of, the elements, ingredients, components or steps.

[00861 Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps, The disclosure of "a" or "one ^* to describe an element, ingredient, component or ste is net intended to foreciose additional elements, ingredients, components or steps.

[0087} Relative positional relationships of elements depicted in the drawings are part of the teachings herein, even if not verbally described. Further, geometries show in the drawings (though not intended to be limiting) are also within the scope of the teachings, even if not verbally described.