Stranded wire harness assembly for steering-by-wire column

Abstract

A vehicle steer-by-wire system includes a column shroud. The steer-by-wire system also includes a steering wheel actuator operably coupled to an end of the column shroud. The steering wheel actuator includes a motor and a spindle that is operably couplable to a steering wheel hub. The steer-by-wire system also includes a rotatable wire harness assembly. The wire harness assembly includes a guide tube at least a portion of which is disposed within an internal cavity defined by the spindle. The wire harness assembly also includes an electrical connection conduit at least a portion of which is disposed within an interior of the guide tube.

Description

Technical Field

[0001] The embodiments described herein relate to vehicle steering systems, and more specifically to stranded wiring harness assemblies for steering-by-wire systems. Background Technology

[0002] Vehicles encompass various types of steering system schemes to allow operators to provide steering inputs to control the vehicle's wheels. Electrical connections are typically made between the steering wheels and other components to provide the various functions associated with them. Wiring harnesses are often used to assist with wiring. Challenges exist in this area because the steering wheels rotate during use. Existing wiring harnesses for rotating applications, such as those utilizing steering wheels, include slip rings and clock springs. Slip rings use sliding electrical contacts to transmit power and signals, but are more prone to noise and limited to straight coaxial paths. Clock springs use flexible, coiled ribbon cables to transmit power and signals. Clock springs are more durable and quieter than slip rings, but are limited by their close proximity to the rotating interface. Summary of the Invention

[0003] According to one aspect of this disclosure, a vehicle steer-by-wire system includes a column sleeve. The steer-by-wire system also includes a steering wheel actuator operatively coupled to an end of the column sleeve, the steering wheel actuator including a motor and a spindle operatively coupled to a steering hub. The steer-by-wire system further includes a rotatable wiring harness assembly. The wiring harness assembly includes a guide tube, at least a portion of which is disposed within a cavity defined by the spindle. The wiring harness assembly also includes an electrical connection conduit, at least a portion of which is disposed within the guide tube.

[0004] According to another aspect of this disclosure, a vehicle steer-by-wire system includes a column sleeve. The steer-by-wire system also includes a steering wheel actuator operatively coupled to an end of the column sleeve, the steering wheel actuator including a motor and a spindle operatively coupled to a steering hub. The steer-by-wire system also includes a rotatable wiring harness assembly. The wiring harness assembly includes a guide tube, at least a portion of which is disposed within a cavity defined by the spindle, wherein the guide tube includes a straight section and a curved section, both of which are tubular to define the interior of the guide tube. The wiring harness assembly also includes a flat ribbon cable, at least a portion of which is disposed within the guide tube. The wiring harness assembly also includes a first bushing. The wiring harness assembly further includes a second bushing, wherein the guide tube extends through the first bushing and the second bushing.

[0005] According to another aspect of this disclosure, a vehicle steer-by-wire system includes a column sleeve. The steer-by-wire system also includes a steering wheel actuator operatively coupled to an end of the column sleeve, the steering wheel actuator including a motor and a spindle operatively coupled to a steering hub. The steer-by-wire assembly also includes a rotatable wiring harness assembly. The wiring harness assembly includes a guide tube, at least a portion of which is disposed within a cavity defined by the spindle, the guide tube including a straight section and a curved section, wherein the straight section is tubular to define the interior of the guide tube, and wherein the curved section is a curved flange section having a flat edge. The wiring harness assembly also includes a flat ribbon cable, at least a portion of which is disposed within the interior of the guide tube, wherein the flat ribbon cable has a first portion configured to contact the flat edge of the curved flange section, wherein the flat ribbon cable enters a first open end of the straight section of the guide tube and extends along the interior of the guide tube together with a second portion of the flat ribbon cable. The wiring harness assembly also includes a first bushing. The wiring harness assembly also includes a second bushing, wherein a guide tube extends through the first bushing and the second bushing.

[0006] According to another aspect of this disclosure, a vehicle steer-by-wire system includes a column sleeve. The vehicle steer-by-wire system also includes a steering wheel actuator operatively coupled to an end of the column sleeve, the steering wheel actuator including a motor and a spindle operatively coupled to a steering hub. The vehicle steer-by-wire system also includes a rotatable wiring harness assembly. The wiring harness assembly includes a guide tube, at least a portion of which is disposed within an interior cavity defined by the spindle, wherein the guide tube includes a straight section and a curved section, both of which are tubular to define the interior of the guide tube. The wiring harness assembly also includes a stranded wire harness extending through the interior of the guide tube. The wiring harness assembly also includes a first bushing. The wiring harness assembly also includes a second bushing, wherein the guide tube extends through both the first bushing and the second bushing.

[0007] These and other advantages and features will become more apparent from the following description taken in conjunction with the accompanying drawings. Attached Figure Description

[0008] The subject matter considered to be the present invention is specifically pointed out and explicitly claimed in the claims at the end of this specification. The foregoing and other features and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0009] Figure 1 The vehicle steering system is illustrated schematically.

[0010] Figure 2 This is a three-dimensional cross-sectional view of a steering wheel actuator used in a vehicle steering system, showing a stranded wire harness assembly.

[0011] Figure 3 This is a 3D view of the guide tube of the stranded wire harness assembly.

[0012] Figure 4 This is a perspective cross-sectional view of a stranded wire harness assembly according to another aspect of this disclosure.

[0013] Figure 5 This is a three-dimensional cross-sectional view of a steering wheel actuator for a vehicle steering system, showing a stranded wire harness assembly according to another aspect of this disclosure.

[0014] Figure 6 This is a three-dimensional view of the bushing of the stranded wire harness assembly.

[0015] Figure 7 This is an elevation end view of a part of a stranded wire harness assembly. Detailed Implementation

[0016] The following discussion pertains to various embodiments of this disclosure. While one or more of these embodiments may be described in more detail than others, the disclosed embodiments should not be construed as or otherwise used to limit the scope of this disclosure (including the claims). Furthermore, those skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is merely illustrative and not intended to imply that the scope of this disclosure (including the claims) is limited to that embodiment.

[0017] First see Figure 1 A vehicle 20 is generally illustrated according to the principles of this disclosure. Vehicle 20 can be any vehicle, such as a car, truck, SUV, minivan, crossover, any other passenger vehicle, any commercial vehicle, or any other suitable vehicle. While vehicle 20 can be a wheeled passenger vehicle intended for use on roads, the principles of this disclosure can be applied to other vehicles, such as airplanes, tractors, boats, or other suitable vehicles. Vehicle 20 may include a propulsion system 30, such as an internal combustion system, an electrical system, or a combination thereof.

[0018] Vehicle 20 includes a steering system 40. The steering system 40 can be configured as a driver-interface steering system, an automatic steering system, or a system that allows both driver-interface and automatic steering. The steering system includes a steering input device 42 (such as a steering wheel), whereby the driver can manually provide steering input by turning the steering wheel. A steering column assembly 44 includes a steering column 45 extending along its axis. A steering wheel actuator (“HWA”) 46 (which may also be referred to as an “emulator”) is provided in the wire-guided steering system and is used to provide feedback and assistance to the steering input device 42 and to receive manual driver input for steering control.

[0019] The steering column 45 includes one or more portions, such as an upper sleeve 48 and a lower sleeve 50. Although two sleeves are shown and described, it should be understood that in some embodiments a single sleeve or three or more sleeves may be provided. Regardless of the number of sleeves, the sleeves may be axially and / or height-adjustable to be movable within a range of positions to meet the user's preference for the positioning of the steering input device 42.

[0020] Wheel actuator (“RWA”) 56 is operatively connected to steering wheel actuator 46. Wheel actuator 56 actuates lateral movement of the vehicle in response to input received from steering wheel actuator 46. Each of steering wheel actuator 46 and wheel actuator 56 may include its own processor and controller, or a single processor may communicate with the respective controller of each of steering wheel actuator 46 and wheel actuator 56.

[0021] Wheel actuator 56 is part of a system that includes an output that drives a rack, ball screw, or any other vehicle-oriented component operatively coupled to wheel 62.

[0022] Historically, continuous mechanical connections spanning multiple components were used to connect steering wheels 42 to vehicle wheels 62. However, steer-by-wire systems eliminate the need for uninterrupted mechanical connections between steering wheels 42 and vehicle wheels 62. For example, in some systems, the steering axle and one or more additional axles (e.g., intermediate axles) connecting to the steering wheels are no longer required. Advances such as those outlined above present new opportunities and challenges in steer-by-wire systems. For instance, certain components can be moved from their traditional locations to new positions within the system.

[0023] See now Figure 2 A portion of a steering system 40 positioned adjacent to a steering wheel 42 is shown. The rear portion of the steering wheel 42 is shown, with a steering wheel actuator 46 operatively coupled to the rear side of the steering wheel 42 (i.e., the wheel side away from the operator). In the illustrated embodiment, the steering wheel actuator 46 is operatively coupled to the rear side of a steering wheel hub 70. The steering wheel actuator 46 includes a motor 100 disposed within a motor housing 102. A spindle 104 is disposed within the motor 100 and shares a coaxial axis of rotation with the motor 100. The steering wheel 42 is mounted to and rotates with a first end 106 of the spindle 104. A second end 108 of the spindle 104 is operatively coupled to an adapter 110. The adapter is operatively coupled to an upper bushing 48. The stability of the spindle 104 during rotation is maintained by a first bushing 112 positioned near the first end 106 of the spindle 104 and a second bushing 114 positioned near the second end 108 of the spindle 104.

[0024] Electrical connections are made between the steering wheel 42 and other vehicle components to provide various functions associated with the steering wheel 42. The embodiments disclosed herein provide a stranded wire harness assembly 120 that maintains a wired electrical connection throughout a large range of rotation of the steering wheel 42.

[0025] The stranded wire harness assembly 120 includes the aforementioned spindle 104 and bushings 112, 114, as well as a guide tube 122 and a flat ribbon cable 124. The guide tube 122 (also...) Figure 3 (As shown in the figure) includes a curved section 126 and a substantially straight portion 128. In some embodiments, the guide tube 122 has a substantially cylindrical cross-section, as shown. Although in some embodiments, the curved section 126 may be continuously curved along its entire length, the curved section 126 may include some non-curved portions.

[0026] The spindle 104 is a hollow component, with a first open end 106 located near the steering hub 70. A second end 108 of the spindle 104 may or may not be open. An inner wall 134 of the spindle 104 defines a cavity 136. A straight portion 128 of a guide tube 122 extends within the cavity 136 along the longitudinal direction of the spindle 104. The guide tube 122 also extends through respective holes defined by a first bushing 112 and a second bushing 114 to stably hold the guide tube 122 in a fixed position.

[0027] A guide tube 122 extends from a first end 138 to a second end 140. The first end 138 is located at the end of a curved section 126 of the guide tube 122. The second end 140 is located at the end of a straight section 128 of the guide tube 122. The first end 138 is located within the steering hub 70. A portion of the length of a flat ribbon cable 124 is disposed within the hollow portion of the guide tube 122. Specifically, the flat ribbon cable 124 extends through the curved portion 126 of the guide tube 122 and extends from the first end 138 of the guide tube 122 for connection to electrical components disposed in or on the steering hub 70. The guide tube 122 includes a ribbon cable outlet slot 150. In the illustrated embodiment, the ribbon cable outlet slot 150 is positioned along the straight section 128 of the guide tube 122. The ribbon cable exit slot 150 passes through the interior of the guide tube 122 and is wound around the outer diameter of the remaining straight section 128 of the guide tube in a direction toward the second end 140 of the guide tube 122. The flat ribbon cable 124 is stress-relieved near the second bushing 114.

[0028] See now Figure 4 According to another aspect of this disclosure, a stranded wire harness assembly is shown, and this stranded wire harness assembly is generally indicated by the numeral 220. Figure 2 and Figure 3Similar to other embodiments, the assembly includes a mandrel 104 and bushings 112, 114. The guide tube 222 of the stranded wire harness assembly 220 includes a substantially straight tube portion 228 and a substantially curved flange portion 226. In some embodiments, the straight tube portion 228 has a substantially cylindrical cross-section, such as... Figure 4 As shown. Although in some embodiments, the curved flange portion 226 may be continuously curved along its entire length, the curved flange portion 226 may include one or more straight portions.

[0029] The straight portion 228 of the guide tube 222 extends within the cavity 136 along the longitudinal direction of the mandrel 104. The straight portion 228 also extends through respective holes defined by the first bushing 112 and the second bushing 114 to stably hold the guide tube 222 in a fixed position.

[0030] The straight portion 228 of the guide tube 222 extends from the first end 238 to the second end 240. The first end 238 is located at the end of the straight portion 228 and near the first bushing 112. The second end 240 is located at the opposite end of the straight portion 228 and near the second bushing 114. The curved flange portion 226 of the guide tube 222 also includes a first end 280 and a second end 282. The first end 280 is located at the end of the curved flange portion 226. The second end 282 is located at the opposite end of the curved flange portion 226. The first end 280 is located within the steering wheel hub 70 and is operatively coupled to the steering wheel 42.

[0031] A portion of the length of the flat ribbon cable 124 is positioned along the flat edge 284 of the curved flange portion 226. Specifically, the flat ribbon cable 124 extends along the flat edge 284 of the curved flange portion 226 and extends to a first end 280 immediately adjacent to the curved flange portion 226 for connection to electrical components disposed in or on the steering hub 70. The flat ribbon cable 124 enters the interior portion of the straight section 228 of the guide tube 222 from the curved flange portion 226. The guide tube 222 includes a ribbon cable exit slot 250 defined by the straight section 228. The flat ribbon cable 124 exits the interior of the straight section 228 through the ribbon cable exit slot 250 and is wound around the outer diameter of the remaining portion of the straight section 228 of the guide tube 222 in a direction toward a second end 240 of the straight section 228. The flat ribbon cable 124 is stress-relieved near the second bushing 114.

[0032] See now Figure 5 According to another aspect of this disclosure, a stranded wire harness assembly is shown, and this stranded wire harness assembly is generally indicated by the numeral 320. Figure 2 and Figure 3Similar to the embodiment shown, the assembly includes a mandrel 104, bushings 112 and 114, and a guide tube 122. In the illustrated embodiment, the guide tube 122 has a bundle of stranded wires 380 disposed within and extending through the interior of the guide tube. A first end 382 of the stranded wires 380 extends from a first end 138 of the guide tube 122, and a second end 384 of the stranded wires 380 extends from a second end 140 of the guide tube 122.

[0033] See now Figure 6 and Figure 7 This illustrates another aspect of the present disclosure that may be incorporated into any embodiment disclosed herein. The first bushing 112 is shown having a recessed portion 190 defined along the outer diameter 192 of the first bushing 112. The recessed portion 190 provides space for airbag wiring to pass through the steering hub 70.

[0034] The embodiments disclosed herein allow full rotation of the steering wheel 42 and associated components without jeopardizing the electrical connections required for the operation of the various features. In some embodiments, rotation of at least 170 degrees in both clockwise and counterclockwise directions is possible while still allowing the transmission of steering wheel control signals and power transmission to features such as heated steering wheels. The embodiments disclosed herein also allow for reductions in materials and costs compared to wiring harness designs that rely on clock springs or slip rings.

[0035] The flat ribbon cable 124 and the bundle of stranded wires 380 may be referred to herein as “electrical connection conduits”.

[0036] Although the invention has been described in detail with reference to only a limited number of embodiments, it is readily understood that the invention is not limited to these disclosed embodiments. Rather, the invention can be modified to include any number of variations, alterations, substitutions, or equivalent arrangements not previously described but commensurate with the spirit and scope of the invention. Furthermore, while various embodiments of the invention have been described, it should be understood that aspects of the invention may include only some of the embodiments described. Moreover, any feature, element, component, or advantage of any embodiment may be used in any other embodiment. Therefore, the invention should not be considered as limited to the foregoing description.

Claims

1. A vehicle steer-by-wire system, comprising: Column sleeve; A steering wheel actuator, operably coupled to the end of the column sleeve, the steering wheel actuator including a motor and a spindle, the spindle being operably coupled to a steering hub; as well as A rotatable wire harness assembly, comprising: A guide tube, at least a portion of which is disposed within the lumen defined by the mandrel; as well as An electrical connection conduit, at least a portion of which is disposed inside the guide tube.

2. The vehicle steer-by-wire system according to claim 1, wherein, The electrical connection conduit is a flat ribbon cable.

3. The vehicle steer-by-wire system according to claim 2, wherein, The guide tube includes a straight section and a curved section, wherein both the straight section and the curved section are tubular to define the interior of the guide tube.

4. The vehicle steer-by-wire system according to claim 3, wherein, The flat ribbon cable passes through the curved section, is positioned inside the guide tube, and is wound along the outer diameter of the straight section.

5. The vehicle steer-by-wire system according to claim 4, wherein, The straight section defines a ribbon cable exit slot, wherein the flat ribbon cable extends through the ribbon cable exit slot.

6. The vehicle steer-by-wire system according to claim 2, wherein, The guide tube includes a straight section and a curved section, wherein the straight section is tubular to define the interior of the guide tube, and the curved section is a curved flange section with a flat edge.

7. The vehicle steer-by-wire system according to claim 6, wherein, The flat ribbon cable has a first portion configured to contact the flat edge of the curved flange segment, wherein the flat ribbon cable enters the first open end of the straight segment of the guide tube and extends along the interior of the guide tube together with a second portion of the flat ribbon cable.

8. The vehicle steer-by-wire system according to claim 7, wherein, The straight section defines a ribbon cable exit slot, wherein the flat ribbon cable extends through the ribbon cable exit slot, and wherein a third portion of the flat ribbon cable is wound along the outer diameter of the straight section.

9. The vehicle steer-by-wire system according to claim 1, wherein, The electrical connection conduit is a stranded wire harness, wherein the guide tube includes a straight section and a curved section, wherein both the straight section and the curved section are tubular to define the interior of the guide tube.

10. The vehicle steer-by-wire system according to claim 9, wherein, The stranded wire harness extends through the guide tube and protrudes from a first open end and a second open end of the guide tube.

11. The vehicle steer-by-wire system according to claim 1, wherein, The guide tube extends through the first bushing and through the second bushing.

12. The vehicle steer-by-wire system according to claim 11, wherein, The first bushing is located inside the first end of the mandrel, and the second bushing is located inside the second end of the mandrel, wherein the first end of the mandrel is located further away from the column sheath relative to the distance between the column sheath and the second end of the mandrel.

13. The vehicle steer-by-wire system according to claim 11, wherein, At least one of the first bushing and the second bushing defines a recessed portion along the outer diameter of the at least one of the first bushing and the second bushing.

14. The vehicle steer-by-wire system according to claim 1, wherein, The steering wheel actuator is operatively connected to the wheel actuator.

15. A vehicle steer-by-wire system, comprising: Column sleeve; A steering wheel actuator, operably coupled to the end of the column sleeve, the steering wheel actuator including a motor and a spindle, the spindle being operably coupled to a steering hub; as well as A rotatable wire harness assembly, comprising: A guide tube, at least a portion of which is disposed within an inner cavity defined by the mandrel, wherein the guide tube includes a straight section and a curved section, wherein both the straight section and the curved section are tubular to define the interior of the guide tube; A flat ribbon cable, at least a portion of which is disposed inside the guide tube; First bushing; and A second bushing, wherein the guide tube extends through the first bushing and the second bushing.

16. The vehicle steer-by-wire system according to claim 15, wherein, The straight section of the guide tube extends through the first bushing and the second bushing.

17. The vehicle steer-by-wire system according to claim 15, wherein, The flat ribbon cable passes through the curved section, is positioned inside the guide tube, and is wound along the outer diameter of the straight section.

18. The vehicle steer-by-wire system according to claim 17, wherein, The straight section defines a ribbon cable exit slot, wherein the flat ribbon cable extends through the ribbon cable exit slot.

19. A vehicle steer-by-wire system, comprising: Column sleeve; A steering wheel actuator, operably coupled to the end of the column sleeve, the steering wheel actuator including a motor and a spindle, the spindle being operably coupled to a steering hub; as well as A rotatable wire harness assembly, comprising: A guide tube, at least a portion of which is disposed within an inner cavity defined by the mandrel, the guide tube comprising a straight section and a curved section, wherein the straight section is tubular to define the interior of the guide tube, and wherein the curved section is a curved flange section having a flat edge; A flat ribbon cable, at least a portion of which is disposed inside the guide tube, wherein the flat ribbon cable has a first portion configured to contact the flat edge of the curved flange segment, wherein the flat ribbon cable enters a first open end of the straight segment of the guide tube and extends along the interior of the guide tube together with a second portion of the flat ribbon cable; First bushing; and A second bushing, wherein the guide tube extends through the first bushing and the second bushing.

20. A vehicle steer-by-wire system, comprising: Column sleeve; A steering wheel actuator, operably coupled to the end of the column sleeve, the steering wheel actuator including a motor and a spindle, the spindle being operably coupled to a steering hub; as well as A rotatable wire harness assembly includes: A guide tube, at least a portion of which is disposed within an inner cavity defined by the mandrel, wherein the guide tube includes a straight section and a curved section, wherein both the straight section and the curved section are tubular to define the interior of the guide tube; A stranded wire harness extends through the interior of the guide tube; First bushing; and A second bushing, wherein the guide tube extends through the first bushing and the second bushing.

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