Intelligent steering kit for traditional steering device

Abstract

A smart steering kit for a legacy steering device for connecting an output shaft of an electric motor to an input shaft of a steering device of a steering system. The kit includes a housing and an adapter assembly having a first adapter assembly end and a second adapter assembly end. The housing includes: a central section having a first central section end and a second central section end, the central section defining an adapter assembly passage extending in a longitudinal direction between the first central section end and the second central section end; an electric motor bracket disposed on the first central section end; and the steering device bracket is arranged on the end part of the second central section. An adapter assembly can be disposed in the adapter assembly channel such that a first adapter assembly end can be connected to the output shaft and a second adapter assembly end can be connected to the input shaft.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to kits and methods that facilitate connecting an electric motor to a steering device of a vehicle steering system. BACKGROUND

[0002] The advent of automated driver assistance systems (“ADAS”) has resulted in the need to modify conventional hydraulic steering systems of vehicles to include electric motors to facilitate automated and non-automated steering of the vehicle. Incorporating electric motors into hydraulic steering systems provides various benefits, including easier steering effort while the vehicle is in motion and at rest, smooth handling and adaptive steering feel from low speeds to high speeds, consistent steering experience regardless of road conditions, excellent reversibility from any turn angle at any vehicle speed while driving forward and backward, and crosswind and road crown compensation, among others.

[0003] Such electric motors are typically mechanically positioned between a steering shaft, which is controlled by an operator of the vehicle through a steering wheel, and a steering device, which converts steering commands input by the driver through the steering wheel into a steering output that moves the steering wheel of the vehicle. By positioning the electric motor in this manner, the electric motor facilitates steering operations of the vehicle. Adding electric motors to hydraulic steering systems greatly expands the ability to control steering of the vehicle and can convert hydraulic steering systems into “smart” steering systems.

[0004] There is a need to develop solutions for more easily integrating electric motors into hydraulic steering systems. SUMMARY

[0005] One aspect of the present disclosure relates to a kit for connecting an output shaft of an electric motor to an input shaft of a steering device, the kit comprising: a housing comprising: a central section having a first central section end and a second central section end, the central section defining an adapter assembly channel, a steering device bracket, and an electric motor bracket, the adapter assembly channel extending in a longitudinal direction between the first central section end and the second central section end, the steering device bracket disposed on the first central section end, the electric motor bracket disposed on the second central section end; and an adapter assembly having a first adapter assembly end and a second adapter assembly end, wherein the adapter assembly is disposable in the adapter assembly channel such that the first adapter assembly end is connectable to the output shaft and the second adapter assembly end is connectable to the input shaft.

[0006] Another aspect of the present disclosure relates to a method for connecting an output shaft of an electric motor to an input shaft of a steering device, the method comprising: connecting an adapter assembly to the output shaft; connecting a housing to the steering device, the housing comprising a central section having a first central section end and a second central section end, the central section defining an adapter assembly passage extending in a longitudinal direction between the first central section end and the second central section end; disposing the adapter assembly in the adapter assembly passage; connecting the adapter assembly to the input shaft; and connecting the housing to the electric motor. BRIEF DESCRIPTION OF DRAWINGS

[0007] Figure 1 A kit for connecting an output shaft of an electric motor to an input shaft of a steering device is shown;

[0008] Figure 2 A kit for connecting an output shaft of an electric motor to an input shaft of a steering device is shown; Figure 1 where the resulting assembly fits to a base frame and a versatile support of a vehicle;

[0009] Figures 3A-3F Details of the housing of the kit of Figure 1 are shown;

[0010] Figures 4A-4D Details of the first adapter component of the kit of Figure 1 are shown;

[0011] Figures 5A-5C Details of the second adapter component of the kit of Figure 1 are shown;

[0012] Figure 6 Details of the adapter assembly of the kit of Figure 1 are shown; Figure 1 a cross-sectional view of the adapter assembly of the kit of is shown;

[0013] Figure 1 Details of the adapter assembly of the kit of Figures 7A-7C are shown;

[0014] Figure 1 How to connect the first adapter component of the kit of Figures 8A-8D to the second adapter component of the kit of Figure 1 is shown;

[0015] Figure 1 How the adapter assembly of the kit of Figures 9A-9E connects to an output shaft of an electric motor is shown;

[0016] Figure 1a housing of the kit of Figures 10A-10B how the housing of the kit of

[0017] Figure 1 a housing of the kit of Figures 11A-11C how the housing of the kit of

[0018] Figure 1 a method of connecting an output shaft of an electric motor to an input shaft of a steering device using the kit of Figure 12

[0019] a view of an assembly resulting from connecting an output shaft of an electric motor to an input shaft of a steering device using the method of Figure 1 Figure 13 another view of an assembly resulting from connecting an output shaft of an electric motor to an input shaft of a steering device using the method of

[0020] Figure 12 Figure 14 various views of an output shaft of an electric motor connected to an input shaft of a steering device using the kit of

[0021] Figure 12 various views of an output shaft of an electric motor connected to an input shaft of a steering device using the kit of Figures 15A-15D and a multi-purpose bracket of a vehicle; and

[0022] Figure 1 another embodiment of the second adapter component of the kit of Figure 16 DETAILED DESCRIPTION

[0023] The kits and methods described herein improve the performance, efficiency, and reliability of conventional hydraulic steering systems by facilitating the incorporation of an electric motor therein.

[0024] Figure 1 A kit 10 for connecting an output shaft of an electric motor to an input shaft of a steering device is shown. The kit 10 can include various components, such as a housing 20, an adapter assembly 36, which can include a first adapter component 42 and a second adapter component 44, and optionally one or more fasteners 50. The one or more fasteners 50 can be any type of fastener known in the art, and different types of fasteners 50 can be included in the kit 10 depending on the particular application for which the fasteners 50 can be used.

[0025] Figure 1 A kit 10 for connecting an output shaft of an electric motor to an input shaft of a steering device is shown. The kit 10 can include various components, such as a housing 20, an adapter assembly 36, which can include a first adapter component 42 and a second adapter component 44, and optionally one or more fasteners 50. The one or more fasteners 50 can be any type of fastener known in the art, and different types of fasteners 50 can be included in the kit 10 depending on the particular application for which the fasteners 50 can be used. Figure 2 is shown. Returning to​​​Figure 6 The steering shaft 100 can be connected to the output shaft 12 of the electric motor 14. An operator of a vehicle equipped with the components described herein can use the steering shaft 100 to provide steering input to the steering mechanism 18 (e.g., via the steering wheel). The steering mechanism 18, in turn, has a sector shaft 104 that can be used to control the vehicle's steering wheel to steer the vehicle. The steering mechanism 18 can be mounted in a multi-function bracket 106. The multi-function bracket 106 can be connected to the vehicle's base frame 102.

[0026] Figure 2 Details of the housing 20 of kit 10 are shown. Housing 20 may include a central section 22 having a first central section end 24 and a second central section end 26. The central section 22 defines an adapter assembly channel 30 extending in a longitudinal direction L between the first central section end 24 and the second central section end 26. The longitudinal direction L extends along the length of housing 20. Housing 20 may include an electric motor bracket 32 ​​disposed on the first central section end 24 and a steering unit bracket 34 disposed on the second central section end 26. Electric motor bracket 32 ​​may include at least one electric motor bracket fastener guide 52 configured to receive a fastener 50. Steering unit bracket 34 may include at least one steering unit bracket fastener guide 54 configured to receive a fastener 50.

[0027] The motor mount 32 may include a plurality of motor mount tabs 56 extending in a radial direction R, which is perpendicular to the longitudinal direction L. Each motor mount tab 56 may include one or more motor mount fastener guides 52 configured to receive a fastener 50. Each motor mount fastener guide 52 may extend in the longitudinal direction L. In one embodiment, the motor mount 32 may have three motor mount tabs 56.

[0028] The steering gear bracket 34 may include a plurality of steering gear bracket tabs 58 extending in the radial direction R. Each steering gear bracket fastener guide 54 may extend in the longitudinal direction L. In one embodiment, the steering gear bracket 34 may have four steering gear bracket tabs 58.

[0029] In one embodiment, the central section 22 of the housing 20 has a first central section portion 60 and a second central section portion 62, the first central section portion 60 having a first inner diameter D. 60 The second central section 62 has a second inner diameter D 62 ,like Figures 3A-3F The clearest example shown is the first inner diameter D. 60 It may not be equal to the second inner diameter D. 62The adapter assembly channel 30 of housing 20 may be defined by a first central section portion 60 and a second central section portion 62.

[0030] like Figure 3D As shown, kit 10 may also include adapter assembly 36 having a first adapter assembly end 38 and a second adapter assembly end 40. Figures 4A-7C As shown, the adapter assembly 36 can be disposed in the adapter assembly channel 30 of the housing 20, such that the first adapter assembly end 38 can be connected to the output shaft 12 of the electric motor 14, and the second adapter assembly end 40 can be connected to the input shaft 16 of the steering device 18. The adapter assembly 36 can be disposed in the adapter assembly channel 30 so as to be concentric with the adapter assembly channel 30.

[0031] In one embodiment, adapter component 36 may include, for example, Figure 6 The first adapter component 42 shown and as... Figures 4A-4D The second adapter component 44 is shown. (As shown) Figures 5A-5C As shown, the first adapter component 42 and the second adapter component 44 can be assembled together (e.g., due to the tolerance fit between them) to form an adapter assembly 36. After assembly, the first adapter component 42 and the second adapter component 44 can be fixed relative to each other (e.g., by welding).

[0032] To facilitate the connection of the second adapter component 44 to the input shaft 16 of the steering device 18, the second adapter component 44 may include a plurality of serrations 46, such as Figures 7A-7C As shown, the plurality of serrations of the second adapter component 44 are configured to engage with the plurality of serrations 46 on the input shaft 16.

[0033] Figures 5A-5C It shows how to use Figures 8A-12 The kit connects the output shaft 12 of the electric motor 14 to the input shaft 16 of the steering device 18. Although these figures envision the adapter assembly 36 including a first adapter component 42 and a second adapter component 44, the adapter assembly 36 may alternatively be a single component.

[0034] Figure 1 Preparation of the adapter assembly 36 is shown, which may include securing the first adapter component 42 to the second adapter component 44. This securing may occur before connecting the adapter assembly 36 to the output shaft 12 of the electric motor 14.

[0035] like Figures 8A-8DAs shown, the flange screw 112 can be inserted into one end of the first adapter component 42, and the dummy standoff portion 114 can be inserted into the other end of the first adapter component 42. The first adapter component 42 can include a shelf 68 on the radially inner side of the first adapter assembly end 38. As Figure 8A shown, the flange screw 112 is inserted into the first adapter component 42 such that the flange screw 112 rests on the shelf 68. Then, as Figure 8B and Figure 8B shown, the flange screw is connected to (e.g., screwed into) the dummy standoff portion 114. In Figure 8D the second adapter component 44 shown in FIG. 8B can then be connected to the first adapter component 42 (e.g., due to a tolerance fit therebetween). The first adapter component 42 and the second adapter component 44 can then be fixed relative to one another (e.g., by welding).

[0036] Figure 8C is shown. The electric motor 14 is shown in its initial state in Figures 9A-9E . As Figure 9A shown, the worm gear assembly 108 is removed from the electric motor 14. The worm gear assembly 108 can include an original output shaft adapter 110. If so, the original output shaft adapter 110 will need to be removed from the output shaft 12 (e.g., by loosening the flange screw 112 and separating the original output shaft adapter 110 from the rest of the worm gear assembly 108). As Figure 9B shown, the adapter assembly 36 can then be placed on the output shaft 12 of the worm gear assembly 108. The flange screw 112 can be used to secure the adapter assembly 36 to the output shaft 12. As Figure 9C shown, the worm gear assembly 108 with the adapter assembly 36 connected can then be attached to the electric motor 14. The resulting assembly is shown in FIG. 9E.

[0037] Figure 9D is shown. As discussed in the context of Figures 10A-10B , the housing 20 can include a steering device bracket 34 disposed on the second central section end 26 of the housing 20. The steering device bracket 34 can include at least one steering device bracket fastener guide 54. Connecting the housing 20 to the steering device 18 can include inserting a fastener 50 through the at least one steering device bracket fastener guide 54 of the steering device bracket 34 and into a steering device fastener guide 64 of the steering device 18, and then securing the fastener 50. Additional fasteners 50 can be similarly secured in other steering device bracket fastener guides 54 and steering device fastener guides 64.

[0038] Figures 3A-3F The housing 20 of the kit 10 is shown disposed between the output shaft 12 of the electric motor 14 and the input shaft 16 of the steering device 18. As Figures 11A-11C indicated by the dashed lines in FIG. 4, upon assembly, the housing 20 will be disposed between the electric motor 14 and the steering device 18.

[0039] As Figure 11A indicated, the second adapter assembly end 50 can include a plurality of serrations 46 configured to engage a plurality of serrations 46 on the input shaft 16. As Figure 9D indicated Figure 11A , connecting the adapter assembly 36 to the input shaft 16 can include inserting the second adapter assembly end 40 of the adapter assembly 36 through the adapter assembly passage 30 of the housing 20, aligning the plurality of serrations 46 on the second adapter assembly end 40 with the plurality of serrations 46 on the input shaft 16, and pressing the second adapter assembly end 40 onto the input shaft 16. When the adapter assembly 36 is disposed in the adapter assembly passage 30, the adapter assembly 36 can be free to rotate within the adapter assembly passage 30.

[0040] After connecting the adapter assembly 36 to the input shaft 16, the housing 20, which has already been connected to the steering device 18, can be connected to the electric motor 14. As discussed in the context of Figure 11C , the housing 20 can include an electric motor mount 32 disposed on the first central segment end 24. The electric motor mount 32 can include at least one electric motor mount fastener guide 52. As such, connecting the housing 20 to the electric motor 14 can include inserting a fastener 50 through the at least one electric motor mount fastener guide 52 of the electric motor mount 32 and the electric motor fastener guide 66 of the electric motor 14, and securing the fastener 50. Additional fasteners 50 can be similarly secured in the other electric motor mount fastener guides 52 and electric motor fastener guides 66.

[0041] Figures 3A-3F More details are shown of how the kit 10 can be used to connect the output shaft 12 of the electric motor 14 to the input shaft 16 of the steering device 18, as discussed in more detail herein.

[0042] Figure 12 The output shaft 12 of the electric motor 14 connected to the input shaft 16 of the steering device 18 using the kit 10 is shown. After such assembly, the electric motor 14 and the steering device 18 can be housed in, for example, a multi-functional mount 106, which can be connected to a base frame 102 of a vehicle, as Figures 13-14 indicated. A steering shaft 100 can then be connected to the output shaft 12 of the electric motor 14.

[0043] Figures 15A-15D Figure 16 Another embodiment of the second adapter component 44 is shown. In this embodiment, the second adapter component 44 includes a second adapter component fastener guide 48 extending in the radial direction R. The second adapter component fastener guide 48 can be used in conjunction with the fastener 50 to secure the second adapter component 44 to, for example, the input shaft 16 of the steering device 18.

[0044] While the application has been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered illustrative or exemplary and not restrictive. It is understood that changes and modifications can be made by those of ordinary skill within the scope of the claims. In particular, it is understood that the present application covers further embodiments with any combination of features from different embodiments described above and below. Additionally, it is understood that the description of the application set forth herein is intended to be illustrative, and not restrictive, of the various ways to represent the application. Many modifications, changes, and variations can be made by those skilled in the art without departing from the spirit of the application, and it is understood that the application is not limited to the order of steps presented in the claims.

[0045] The terminology used in the detailed description of the application herein should not be taken as limiting the scope of the application. For example, the use of the ordinal adjectives "first" and "second" do not imply a sequence or order unless explicitly stated, unless explicitly stated otherwise. Similarly, the use of the articles "a" and "an" do not imply a limitation on the number of entities to which the articles refer unless explicitly stated otherwise. As used herein, the article "a" is intended to be synonymous with "one or more" or "at least one." Also, the use of the term "including" as well as other forms for example, "include," "includes," "has," "has," "having," "comprise," "comprises," or "comprising" should be considered inclusive or open ended and not exclusive or limiting. That is, the term "comprising" should be construed to cover also "consisting of." Moreover, the use of the term "or" should be considered as a comprehensive inclusive term, i.e., the use of "or" in a list of two or more items should be considered as an inclusive OR, i.e., the group of items derived by either including all of the items in the list or including only one of the items in the list. For example, the phrase "A, B, or C" should be interpreted as a disjunctive list of alternatives, i.e., as "A or B or C" and not as "A or B or C or" unless expressly stated otherwise.

[0046] List of Reference Signs

[0047] 10 kit

[0048] 12 output shaft

[0049] 14 electric motor

[0050] 16 input shaft

[0051] 18 steering device

[0052] 20 housing

[0053] 22 central section

[0054] 24 first central section end

[0055] 26 second central segment end

[0056] 30 adapter assembly passage

[0057] 32 electric motor mount

[0058] 34 steering device mount

[0059] 36 adapter assembly

[0060] 38 first adapter assembly end

[0061] 40 second adapter assembly end

[0062] 42 first adapter component

[0063] 44 second adapter component

[0064] 46 sawtooth

[0065] 48 second adapter component fastener guide

[0066] 50 fastener

[0067] 52 electric motor mount fastener guide

[0068] 54 steering device mount fastener guide

[0069] 56 electric motor mount tab

[0070] 58 steering device mount tab

[0071] 60 first central segment portion

[0072] 62 second central segment portion

[0073] 64 steering device fastener guide

[0074] 66 electric motor fastener guide

[0075] 68 shelf

[0076] 100 steering shaft

[0077] 102 base frame

[0078] 104 spider shaft

[0079] 106 multi-functional mount

[0080] 108 worm gear assembly

[0081] 110 original output shaft adapter

[0082] 112 flange screw

[0083] 114 dummy support member

[0084] L longitudinal direction

[0085] R radial direction

[0086] C 60 inner diameter of the first central section portion 60

[0087] C 62 inner diameter of the second central section portion 62.

Claims

1. A kit for connecting the output shaft of an electric motor to the input shaft of a steering device, the kit comprising: The housing includes: A central section having a first central section end and a second central section end, the central section defining an adapter assembly channel extending longitudinally between the first central section end and the second central section end. Electric motor bracket, the electric motor bracket being disposed at the end of the first central section, and Steering device bracket, the steering device bracket being disposed at the end of the second central section; and An adapter assembly having a first adapter assembly end and a second adapter assembly end. The adapter assembly can be disposed in the adapter assembly channel such that the end of the first adapter assembly can be connected to the output shaft, and the end of the second adapter assembly can be connected to the input shaft.

2. The kit according to claim 1, wherein, The adapter component can be positioned within the adapter component channel so as to be concentric with the adapter component channel.

3. The kit according to claim 1, wherein, The adapter assembly includes a first adapter component and a second adapter component, and The first adapter component and the second adapter component are fixed relative to each other.

4. The kit according to claim 3, wherein, The first adapter component is configured to connect to the output shaft, and The second adapter component is configured to be connected to the input shaft.

5. The kit according to claim 4, wherein, The second adapter component includes a plurality of saw teeth configured to engage with a plurality of saw teeth on the input shaft.

6. The kit of claim 1, further comprising: At least two fasteners, The electric motor bracket includes at least one electric motor bracket fastener guide, which is configured to receive a first fastener of the at least two fasteners. The steering device bracket includes at least one steering device bracket fastener guide, which is configured to receive a second fastener of the at least two fasteners.

7. The kit according to claim 1, wherein, The electric motor bracket includes a plurality of electric motor bracket tabs extending in the radial direction. Each of the plurality of electric motor bracket tabs includes an electric motor bracket fastener guide configured to receive fasteners, and Each electric motor bracket fastener guide extends in the longitudinal direction.

8. The kit according to claim 7, wherein, The plurality of electric motor support tabs includes three electric motor support tabs.

9. The kit according to claim 1, wherein, The steering mechanism bracket includes a plurality of steering mechanism bracket tabs extending in the radial direction. Each of the plurality of steering gear bracket tabs includes a steering gear bracket fastener guide configured to receive a fastener, and Each steering device bracket fastener guide extends in the longitudinal direction.

10. The kit according to claim 9, wherein, The plurality of steering device bracket tabs includes four steering device bracket tabs.

11. The kit according to claim 1, wherein, The central section includes a first central section portion having a first inner diameter and a second central section portion having a second inner diameter, and Wherein, the first inner diameter is not equal to the second inner diameter.

12. The kit according to claim 3, wherein, The second adapter component includes a second adapter component fastener guide extending in the radial direction.

13. A method for connecting the output shaft of an electric motor to the input shaft of a steering device, the method comprising: Connect the adapter assembly to the output shaft; The housing is connected to the steering device, the housing including a central section having a first central section end and a second central section end, the central section defining an adapter assembly channel extending in a longitudinal direction between the first central section end and the second central section end; The adapter component is set in the adapter component channel; Connect the adapter assembly to the input axis; as well as Connect the housing to the electric motor.

14. The method according to claim 13, wherein, The adapter assembly includes a first adapter component and a second adapter component, and The method further includes securing the first adapter component to the second adapter component before connecting the adapter assembly to the output shaft.

15. The method according to claim 13, wherein, The adapter assembly has a first adapter assembly end and a second adapter assembly end. Wherein, the first adapter assembly end includes a shelf on the radially inner side of the first adapter assembly end, and Connecting the adapter assembly to the output shaft includes: The end of the first adapter assembly is positioned on the output shaft. Insert the flange screw into the end of the first adapter assembly such that the flange screw rests on the shelf, and Secure the flange screw to the output shaft.

16. The method according to claim 13, wherein, The housing includes a steering gear bracket disposed at the end of the second central section, the steering gear bracket including at least one steering gear bracket fastener guide, and Connecting the housing to the steering device includes: Insert the fastener through the at least one steering gear bracket fastener guide and the steering gear fastener guide of the steering gear, and Secure the fastener.

17. The method according to claim 13, wherein, The adapter assembly has a first adapter assembly end and a second adapter assembly end. The second adapter assembly includes a plurality of serrations at its end, the serrations being configured to engage with a plurality of serrations on the input shaft, and Connecting the adapter assembly to the input shaft includes: Insert the end of the second adapter component through the adapter component channel. Align the plurality of serrations on the end of the second adapter assembly with the plurality of serrations on the input shaft, and Press the end of the second adapter assembly onto the input shaft.

18. The method according to claim 17, wherein, When the adapter component is disposed in the adapter component channel, the adapter component is able to rotate freely within the adapter component channel.

19. The method according to claim 13, wherein, The housing includes an electric motor bracket disposed at the end of the first central section, the electric motor bracket including at least one electric motor bracket fastener guide, and Connecting the housing to the electric motor includes: The fastener is inserted through the at least one electric motor bracket fastener guide and the electric motor fastener guide of the electric motor, and Secure the fastener.

20. The method according to claim 13, wherein, The housing includes an electric motor bracket disposed at the end of the first central section, the electric motor bracket including a plurality of electric motor bracket tabs extending in the radial direction. Each of the plurality of motor bracket tabs includes a motor bracket fastener guide configured to receive a fastener, and each motor bracket fastener guide extends in the longitudinal direction. The housing includes a steering mechanism bracket disposed at the end of the second central section, the steering mechanism bracket including a plurality of steering mechanism bracket tabs extending in the radial direction, and Each of the plurality of steering bracket tabs includes a steering bracket fastener guide configured to receive a fastener, and each steering bracket fastener guide extends in the longitudinal direction.

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