Integrated flexible coupling

Abstract

The utility model relates to the technical field of automobile electric steering engines, in particular to an integrated flexible coupler which comprises two hard bases and a soft middle ring, the two hard bases and the soft middle ring are of an integrated injection molding structure, a round boss is arranged on the side, close to the soft middle ring, of each hard base, a circle of annular protruding lugs are arranged on the outer surface of each round boss, and the annular protruding lugs are arranged on the outer surface of each round boss. The flexible middle ring wraps the round boss, the annular protruding lug is embedded into the inner surface of the flexible middle ring, a spline inner hole is formed in the hard base in the axial direction, the shore hardness of the flexible middle ring is 40-65, and the shore hardness of the hard base is 80-90. Compared with the prior art, the number of parts is reduced, and the production takt is optimized; part gaps generated in the assembling process are eliminated, the transmission efficiency of the motor shaft and the worm shaft is improved, abrasion between parts is avoided, and the NVH performance of the electric steering engine is improved; the rigidity difference between the hard base and the soft middle ring is utilized to achieve the function of a flexible coupling, and the deviation between the motor shaft and the worm shaft is further eliminated.

Description

Technical Field

[0001] The utility model relates to the technical field of automobile electric steering gears, in particular to an integrated flexible coupling. Background Art

[0002] In the design of a dual-pinion electric power steering gear, the coupling is a key component used to transmit torque between the motor and the worm. The coupling's design objective is to transfer the torque of the power-assistance unit's motor to the worm, thereby ensuring the proper functioning of the steering gear.

[0003] At present, the coupling is composed of three parts: motor gear hub 1, gear ring 2, and worm gear hub 3. Figure 1 The motor gear hub 1 and the worm gear hub 3 are assembled on the motor shaft and the worm shaft respectively through spline fitting, and the ring gear 2 serves as an intermediate piece to connect the motor gear hub 1 and the worm gear hub 3.

[0004] During the actual assembly process, the motor hub 1 is assembled to the motor shaft, followed by one side of the ring gear 2 and the motor hub 1. The worm hub 3 is then assembled to the worm, and the other side of the ring gear 2 is assembled to the worm hub 3. Gaps often exist between the motor hub 1 and the ring gear 2, and between the worm hub 3 and the ring gear 2. Over extended operation, wear on the components increases these gaps, creating a risk of noise and leading to user complaints.

[0005] Therefore, it is necessary to design an integrated flexible coupling to eliminate the gap between parts generated during the assembly process, avoid wear between parts, and improve the NVH performance of the electric steering gear. Summary of the Invention

[0006] The purpose of the utility model is to overcome the deficiencies of the prior art and provide an integrated flexible coupling to eliminate the gaps between parts generated during the assembly process, avoid wear between parts, and improve the NVH performance of the electric steering gear.

[0007] In order to achieve the above-mentioned purpose, the utility model is an integrated flexible coupling, including a hard base and a soft middle ring. The two hard bases and the soft middle ring are an integrated injection molding structure. The hard base has a circular boss on the side close to the soft middle ring. The outer surface of the circular boss is provided with a circle of annular lugs. The soft middle ring is covered on the outside of the circular boss, and the annular lugs are embedded in the inner surface of the soft middle ring. The interior of the hard base is provided with a spline inner hole along the axial direction. The Shore hardness of the soft middle ring is 40~65, and the Shore hardness of the hard base is 80~90.

[0008] The two rigid bases are respectively assembled with the spline structure of the motor shaft and the spline structure of the worm.

[0009] The one-piece injection molding structure is a two-shot injection molding structure.

[0010] The melting temperature of the soft middle ring is at least 70°C lower than the melting temperature of the hard base.

[0011] Compared with existing technologies, this new design reduces the number of parts, eliminates the need for alignment between the hub and ring gear, and optimizes production cycle time. It eliminates gaps between parts during assembly, improves the transmission efficiency of the motor shaft and worm shaft, avoids wear between parts, and improves the NVH performance of the electric power steering gear. By utilizing the rigidity difference between the rigid base and the flexible center ring to achieve the function of a flexible coupling, it further eliminates misalignment between the motor shaft and worm shaft. This new design offers the advantages of a simple structure, a simple production process, high versatility, and excellent reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a structural diagram of the prior art.

[0013] Figure 2 It is a structural diagram of the present utility model.

[0014] Figure 3 This is an exploded view of the integrated flexible coupling of the utility model.

[0015] Figure 4 It is a left view of the integrated flexible coupling of the utility model. DETAILED DESCRIPTION

[0016] The present invention will now be further described with reference to the accompanying drawings.

[0017] See also Figure 2 、 Figure 3 and Figure 4 The present invention is an integrated flexible coupling comprising a rigid base and a flexible center ring. The rigid base 61 and the flexible center ring 62 are integrally injection-molded. The rigid base 61 has a circular boss 63 on the side closest to the flexible center ring 62. The outer surface of the circular boss 63 is provided with a ring of annular lugs 64. The flexible center ring 62 wraps around the circular boss 63. The annular lugs 64 are embedded in the inner surface of the flexible center ring 62 to enhance the connection strength between the circular boss 63 and the flexible center ring 62. A splined inner hole 65 is axially defined within the rigid base 61. The flexible center ring 62 has a Shore hardness of 40-65 and is made of soft plastic or rubber. The rigid base 61 has a Shore hardness of 80-90. The rigid base 61 is made of hard plastic.

[0018] The two rigid bases 61 are assembled with the spline structures of the motor shaft 4 and the spline structures of the worm 5, respectively, to achieve the connection between the motor shaft 4 and the worm 5. During use, if there is any deviation between the axes of the motor shaft 4 and the worm 5, the soft center ring 62, due to its low hardness, will compensate for the deviation between the axes of the motor shaft 4 and the worm 5, thereby improving the transmission efficiency of the motor shaft and the worm shaft.

[0019] The integrated injection molding structure is a two-shot process. The two rigid bases 61 are first injection-molded separately, then placed into the mold for a secondary injection molding process, completing the molding of the soft center ring 62. This secondary injection molding process not only ensures the rigidity difference between the rigid base 61 and the soft center ring 62, but also eliminates the gap between the rigid base 61 and the soft center ring 62 during assembly, preventing wear between the parts and improving the NVH performance of the electric power steering gear.

[0020] In order to better achieve secondary injection molding, the melting temperature of the soft middle ring 62 is at least 70° C. lower than the melting temperature of the hard base 61 .

[0021] This new design reduces the number of parts, eliminates the need for alignment between the hub and ring gear, and optimizes production cycle time. It eliminates gaps between parts during assembly, improves the transmission efficiency of the motor shaft and worm shaft, avoids wear between parts, and improves the NVH performance of the electric power steering gear. By utilizing the rigidity difference between the rigid base and the flexible center ring to achieve the function of a flexible coupling, it further eliminates misalignment between the motor shaft and worm shaft. This new design offers the advantages of a simple structure, a simple production process, high versatility, and excellent reliability.

Claims

1. An integrated flexible coupling, comprising a hard base and a soft middle ring, characterized in that: The two rigid bases (61) and the soft middle ring (62) are an integral injection-molded structure. The rigid base (61) has a circular boss (63) on one side close to the soft middle ring (62). The outer surface of the circular boss (63) is provided with a circle of annular lugs (64). The soft middle ring (62) is wrapped around the outside of the circular boss (63). The annular lugs (64) are embedded in the inner surface of the soft middle ring (62). A spline inner hole (65) is provided in the interior of the rigid base (61) along the axial direction. The Shore hardness of the soft middle ring (62) is 40-65, and the Shore hardness of the rigid base (61) is 80-90.

2. The one-piece flexible coupling according to claim 1, characterized in that: The two rigid bases (61) are respectively assembled with the spline structure of the motor shaft (4) and the spline structure of the worm (5).

3. The one-piece flexible coupling according to claim 1, characterized in that: The one-piece injection molding structure is a two-shot injection molding structure.

4. The integrated flexible coupling according to claim 3, characterized in that: The melting temperature of the soft middle ring (62) is at least 70°C lower than the melting temperature of the hard base (61).

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