Method and apparatus for aligning turn signal switch

A method and apparatus for aligning a turn signal switch housing with respect to a cancellation pin support bracket includes installation of the bracket on a steering wheel hub. The bracket includes a gauge pin formed in one piece with the steering wheel hub ring bracket. The ring bracket supports cancellation pins to extend at radially displaced positions for registering with the actuator of the turn signal switch assembly. The turn signal switch assembly is supported upon the steering column housing by a mount for adjusting the axial position of the housing. In the preferred embodiment, the gauge pin is carried by the hub-mounted ring bracket and is positioned for engagement with an engagement surface on the turn signal housing adjacent the actuator to be operated by the cancellation pin. The switch housing is slid axially along the steering column housing while supported in a mounting bracket. The fasteners are then tightened to secure the turn signal housing to the steering column housing in a position necessary to rotate the cancellation pin in an arcuate path that intersects with the actuator on the turn signal switch housing.

TECHNICAL FIELD 
The present invention relates generally to motor vehicle turn signal 
switches, and more particularly to the alignment of a turn signal switch 
cancellation mechanism with respect to the switch housing mounted to the 
steering column housing. 
BACKGROUND ART 
Turn signal switch assemblies are well-known, and often include a 
self-cancelling mechanism carried by the steering wheel hub for engagement 
with an actuator on the turn signal switch assembly. The switch assembly 
is often rigidly mounted to the exterior of the steering column housing, 
although some switch cancellation assemblies are mounted interiorly of an 
exterior housing. However, the interior structures are generally more 
complicated so as to fit within the housing; and must be supplied as 
original equipment with the vehicles. In addition, access to such 
structures is obstructed, and thus substantially increases the labor, 
expense and time necessary to diagnose or repair problems in the turn 
signal and cancellation mechanism. 
Externally mounted turn signal switch assemblies provide appreciable cost 
savings by simplicity in the original manufacturing and assembly, as well 
as in the case of repairing or replacing components of the switch assembly 
as shown in U.S. Pat. Nos. 4,013,850 and 3,809,833. Both of these patents 
disclose directional signal assemblies mounted to the steering column 
housing by a strapping clamp. In the self-cancelling turn signal system of 
U.S. Pat. No. 4,013,850, a pin rotates with the steering wheel hub so that 
it passes through a path intersecting a lever arm position on the exterior 
of the switch housing assembly. Unfortunately, the position of the switch 
housing along the axis of the steering column is dependent wholly upon the 
abilities of the installer to estimate a proper alignment and secure the 
strap clamp in the desired position. Accordingly, the cancellation pin may 
miss or make only partial contact with the lever. Misalignment may 
accelerate the wear of the contacting parts, or cause deformation or 
misalignment of the pin and lever contact point which interferes with 
proper operation of the turn signal or the cancellation mechanism. 
In order to avoid arbitrary alignments of the switch housing with respect 
to the cancellation mechanism on the hub, attempts have been made to 
insert gauge blocks that position the lever at a fixed position relative 
to the rotatable hub that carries the cancellation pin. However, such 
alignment is extremely laborious and difficult since an operator who has 
secured a cancellation assembly in position on the hub must hold the 
switch housing while aligning the housing and also tightening the fastener 
to attach the switch housing to the steering column housing. Accordingly, 
an installer finds it difficult to hold and retain another item such as a 
gauge block between the relatively small surfaces between the hub and the 
switch housing, particularly where the housing must be properly positioned 
along an inclined axis of the steering column. In fact, use of alignment 
gauges would substantially increase the time for installation of the turn 
signal assembly, particularly if the housing may be initially secured to 
the steering column housing, then loosened to permit insertion of a gauge 
between the hub and the actuator. Such loosening or tightening to attempt 
alignment of the switch housing with respect to the cancellation mechanism 
carried on the hub can be extremely difficult due to the dashboard 
spacing, interior layout and other controls at the steering column. In 
addition, the cancellation pin is generally mounted diametrically away 
from the switch housing relative to the steering column and cannot 
contribute to alignment of the pin within the path of the exposed 
actuator. Moreover, unless the hub is also turned for alignment it would 
be extremely difficult for a single installer to position the cancellation 
pin toward the switch housing while holding the housing and tightening the 
fastener carried at an end of the strap clamp. 
SUMMARY OF THE INVENTION 
The present invention overcomes the above-mentioned disadvantages by 
providing a method and apparatus for aligning the turn signal switch 
assembly, carried by the steering column housing, with the cancellation 
actuator rotatably carried by the steering wheel hub. In general, a gauge 
pin is formed with one of the switch mounting components so that a 
cancellation pin is rotated at a radially extended position for arcuate 
path registration with an actuator positioned on an exposed surface on the 
turn signal housing. The present invention simplifies and eases the 
installation procedures required to properly align the turn signal housing 
with the cancellation mechanism. Accordingly proper installation of one 
portion of the apparatus guides alignment of the other portion for 
immediate, simplified installation. 
In the preferred embodiment, a steering wheel hub cancellation bracket body 
includes a gauge pin extending axially at a radially extended position for 
arcuate path registration with an actuator to be mounted for support by 
the steering column. The hub bracket includes an alignment surface, 
preferably a radially extended annular surface, to abut against a radially 
extending abutment surface of the hub. Fasteners, for example, 
self-threading screws or the like, may be used to install the cancellation 
bracket body to the steering wheel hub and support the cancellation 
member, preferably in the form of a resiliently protruding pin extending 
axially along the steering column. 
In addition, the preferred embodiment includes turn signal housing mount 
for supporting the switch assembly housing, and for axially adjusting the 
position of the housing with respect to the steering column housing while 
the turn signal switch housing is wholly supported by the steering column 
housing. Particularly, the turn signal switch housing may be bolted to a 
bracket secured to the steering column housing. The mount provides support 
for the turn signal switch housing during installation and alignment of 
the switch housing. The housing may include a nut in a captured cavity for 
sliding displacement along the axis of the steering column, the nut having 
a threaded opening that registers with axially aligned, elongated slots in 
a wall of the switch housing. Threaded fasteners are inserted to extend 
through stem-sized openings in a bracket mounted to the steering column 
housing and into the nut through the wall openings. Alternatively, the 
steering column bracket may include elongated slots adapted to receive 
bolt stems, the bolt stems being threaded into apertures formed in the 
turn signal switch housing. In either event, the turn signal switch 
housing remains slidably adjustable along the axis of the steering column 
housing. Moreover, the switch housing is supported by the steering column 
housing during the alignment with the cancellation mechanism. 
As a result, the present invention provides a method for installing and 
aligning a turn signal cancellation mechanism with a turn signal switch 
housing in which gauge pins carried by one of the parts is positioned 
against an exposed surface on the other part. For example, a switch 
assembly is positioned at a mount in the form of a bracket carried by the 
steering column housing. The switch assembly has an exposed actuator and a 
gauge surface adjacent the actuator. An engager, preferably in the form of 
an arcuate bracket, is secured to the steering wheel hub by positioning an 
alignment surface against a corresponding abutment surface on the hub and 
securing the engager to the hub. When the hub bracket includes the 
removable gauge pin, the turn signal switch housing is axially displaced 
along the mount in the direction of the steering column axis, while being 
supported by the mount, until the gauge pin abuts against the gauge 
surface adjacent the actuator. When the switch housing is positioned by 
abutment with the gauge pin, the switch assembly housing is secured 
tightly in position at the mount by complete installation of the 
fasteners. In the preferred embodiment, the gauge pin is formed in one 
piece with this bracket, preferably made of a plastic material, so that 
the gauge pin can be easily clipped for removal from the bracket. When the 
gauge pin is removed, only the cancellation member remains exposed for 
contact with the actuator on the turn signal switch housing. 
As a result, the present invention provides an advantageous method and 
apparatus for simplifying and easing installation of a self-cancellation 
turn signal assembly carried exteriorly of the steering column housing. In 
addition, the present invention provides more accurate alignment of the 
turn signal cancellation mechanism by a single installer as it relieves 
the need to measure or manipulate gauges while mounting the turn signal 
housing and the cancellation mechanism at the steering column. Moreover, 
the present invention avoids the tendency of the cancellation housing to 
change positions along the axis of the steering column when the turn 
signal housing is not tightly engaged with the mount at the steering 
column. Moreover, the present invention avoids the opportunity for 
misalignment of the cancellation pin with respect to an actuator exposed 
on a turn signal switch housing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring first to FIG. 1, a turn signal assembly 10 with self-cancellation 
includes a turn signal switch assembly housing 12 carried by a steering 
column housing 14 by mount 16, as well as a cancellation assembly 18 
carried by the steering wheel hub 20. Each of these elements may be 
constructed in conventional manners, for example, as disclosed in U.S. 
Pat. Nos. 4,013,850 or 4,081,634 incorporated by reference. Of course, 
additional features particularly pertaining to the present invention will 
be discussed in detail for the purposes of illustration of features 
applicable to the present invention. 
As best shown in FIG. 1, the cancellation device 18 comprises a ring 
bracket 22 including an annular, semi-circular ring wall 24, a radially 
extending annular wall 26 and a reinforcement ring 28. The ring bracket 22 
carries a pair of socket bosses 30 at diametrically opposed positions for 
supporting cancellation pins in a manner to be discussed in detail below. 
The turn signal assembly housing 12 carries a pivoted lever 32 for 
controlling the operation of turn signal switches carried within the 
housing in a well-known manner. As is also previously known, the housing 
12 carries an actuator 34 exposed to registration with a cancellation pin 
in the arcuate path 35 followed by the cancellation pin carried in the 
boss 30. The actuator 34, for example, lever 36, pivoted beneath the cover 
38, extends between the arms 40 and 42 of lever 32. These parts form a 
position calibrated turn signal switch. Lever 36 is forced to pivot when 
engaged by a pin to control the internal turn signal electrical switch. By 
mechanically engaging arms 40, 42 when the arms are aligned in an actuated 
position, the handle 32 returns to the position shown in the drawing in a 
well known manner, to disengage the internal electrical switch. 
The actuator 34 is exposed adjacent an engagement surface 44 on the housing 
12 so that the actuator 34 intersects with the path 35 of the cancellation 
pins. The switch housing 12 could be fabricated using thermoplastic 
materials such as polycarbonate, nylon, polyester, polyphenylene-sulfide, 
etc., in either reinforced or unreinforced composition. Ferrous materials 
such as alloy steel, carbon steel, cast iron, stainless steel, etc. could 
also be used. Nonferrous metals such as aluminum and its alloys, zinc and 
its alloys, etc. could also be used and the bracket could be of a 
machined, cast, extruded, sintered, die drawn or molded construction. The 
lever component could be fabricated using thermoplastics such as 
polycarbonate, nylon, polyester, etc., in either reinforced or 
unreinforced composition. Ferrous materials such as alloy steel, carbon 
steel, cast iron, stainless steel, etc. could also be used. Nonferrous 
metals, such as aluminum and its alloys, zinc and its alloys, etc. could 
be used. It could be of a molded, sintered, die cast, die stamped, cold 
formed or extruded construction. The lever spring component could be any 
force generating device such as a torsion spring, extension spring, 
compression spring, wave washer, compressed air or gas actuated plunger, 
leaf spring, etc. 
A bracket 50 is secured to the steering column housing 14, for example, by 
welds or other fasteners. In the preferred embodiment, the bracket 50 
includes the weld mounted base flange and side flanges with openings 
adapted to receive the stem of bolts 52 in a fixed position. 
As best shown in FIGS. 3 and 4, the housing 12 includes a pair of cavities 
54 adapted to receive adjustable nuts 56. Each nut 56 includes at least 
one threaded opening adapted to receive bolt 52 for registration with 
elongated slots 58 in a side wall of the housing 12 forming a periphery of 
the cavity 54. The adjustable nut or nuts could be fabricated using 
ferrous materials such as alloy steel, carbon steel, cast iron, stainless 
steel, etc. Nonferrous metals such as aluminum and its alloys, zinc and 
its alloys, copper and its alloys, etc. could also be used. Thermoplastics 
such as polyphenylene-sulfide, polycarbonate, nylon, etc., in either 
reinforced or unreinforced composition, could be used. It could be of a 
machined, die stamped, extruded, sintered or molded construction. Holes to 
accept screw fasteners could be tapped for threading, or smooth to accept 
self tapping type fasteners. Other detail, such as slots, could be formed 
into the part to accept a variety of securement means. 
The cavity 54 is closed at one end, for example, a top wall 60 as shown in 
FIG. 4, and a retainer cap 61 closes the open bottom of the cavity 54. The 
retainer cap 61 is installed after insertion of the nut to capture the nut 
56 within the cavity 54. The cover and other retaining means could be 
fabricated using thermoplastics such as polycarbonate, nylon, polyester, 
etc. in either reinforced or unreinforced composition. Ferrous materials 
such as alloy steel, carbon steel, cast iron, stainless steel, etc., could 
be used. Nonferrous metals such as aluminum and its alloys, zinc and its 
alloys, etc. could also be used. These parts could be of molded, extruded, 
die cast, sintered or die stamped construction. Although the nut is 
slidable along the axis of the steering column as shown by the directional 
arrow 63 in FIG. 4, the nut is otherwise restrained from rotation within 
the cavity by squared or otherwise configured mating surfaces which engage 
the wall of the housing against the flanges of the bracket 50. 
Referring now to FIG. 5, the ring bracket 22 is formed in one piece with a 
gauge pin 62. The steering wheel hub mounted cancelling mechanism housing 
could be fabricated using thermoplastics, such as polycarbonate, 
polyester, nylon, ABS, acetal, etc. in either reinforced or unreinforced 
composition. Ferrous materials such as alloy steel, carbon steel, cast 
iron, stainless steel, etc. could also be used. Nonferrous metals such as 
aluminum and its alloys, zinc and its alloys, etc. could be used. It could 
be of a molded die cast, sintered, extruded or die drawn construction. 
The bracket preferably has two gauge pins positioned at symmetrical 
intervals with respect to the cancellation pins 48. As shown in 
cross-section in FIG. 5, boss 30 defines a cavity 70 carrying a spring 
such as a coil spring 72 pressing against a pin stud 74. The pin stud 74 
includes an enlarged head retained within the chamber 70 by a retainer 
sleeve 76. The pin or pins could be fabricated using thermoplastics such 
as polycarbonate, nylon, acetal, ABS, etc. in either reinforced or 
unreinforced composition. Ferrous materials such as alloy steel, carbon 
steel, cast iron, stainless steel, etc. could also be used. Nonferrous 
metals such as aluminum and its alloys, zinc and its alloys, copper and 
its alloys, etc. could be used. The pin or pins could be of molded, cold 
formed, sintered, die cast, machined or die drawn construction. The pin 
spring or springs could be any force generating device, such as a 
compression spring, extension spring, torsion spring, wave washer, 
compressed air or gas actuated plunger, leaf spring, etc. The retainer or 
retainers means could be fabricated using thermoplastics such as 
polycarbonate, nylon, ABS, acetal, polyester, etc., in either reinforced 
or unreinforced composition. Ferrous materials such as carbon steel, alloy 
steel, stainless steel, cast iron, etc. could be used. Nonferrous metals 
such as aluminum and its alloys, zinc and its alloys, etc. could also be 
used. These parts could be of a molded, extruded, cold formed, die 
stamped, die drawn, die cast or machined construction. 
The turn signal cancellation members then are installed by passing the 
semi-circular ring 22 over the hub and then axially displacing the ring 
bracket 22 until the annular wall 26 engages against the abutment surface 
86. The ring bracket 22 is secured in position by self-tapping screws 78. 
The turn signal switch assembly housing 12 may be supported in a mounting 
position by the bracket 50 by engagement of the bolts 52 in the openings 
in the bracket 50 and through the slots 58 in the housing wall into 
engagement with the nuts 56. As a result, the turn signal housing is 
supported at an approximate axial position with regard to the cancellation 
pin 48. As a result, the turn signal housing 12 can be more easily 
positioned in a proper axial alignment with respect to the cancellation 
pin 48 by means of the gauge pin 62. 
In particular, the housing 12 may be axially displaced as the nuts 56 move 
in cavities 54. The housing 12 is manipulated to move toward and into 
abutment with the gauge pin 62 to properly position the exposed engagement 
surface 44. More particularly, the actuators 34 in the form of lever 36 
are then positioned in proper alignment for engagement with the 
cancellation pin 48. The bolts 52 are then tightened to accurately align 
and securely position the turn signal housing 12 on the steering column 
housing 14 in operable positions for engagement with the cancellation pin 
48. As a result, the installer does not have to physically support the 
turn signal housing 12 while simultaneously attempting to fasten the 
housing to the steering column housing 14 and estimating the alignment 
required to properly engage the cancellation pins 48 with the actuator 34 
exposed above the gauge surface 44. 
Having thus described the present invention, many modifications thereto 
become apparent to those skilled in the art to which it pertains without 
departing from the scope and spirit of the present invention. For example, 
an alignment process may also be practiced with elongated slots 58 in the 
bracket 50, for example, if the slots shown in hidden line in FIGS. 1 and 
5 were shown in solid line in that figure. In such a construction, the 
bolts 52 would fit in threaded apertures within the wall of the housing 
12. However, the use of adjustable nuts 56 provides substantially greater 
support for the housing 12 while it is being supported and aligned for 
final connection to the steering column housing 14.