TURNTABLE SYSTEMS

Abstract

This document reveals rotary steering systems.An exemplary vehicle steering system includes an input gear attached to one end of an input shaft, a first intermediate gear attached to a first pinion and meshing with the input gear, a second intermediate gear attached to a second pinion and meshing with the first intermediate gear or a third intermediate gear, a motor attached to a third pinion, a motor attached to a third pinion, the third pinion meshing with the second intermediate gear and the motor rotating the first intermediate gear and the first pinion, a third gear attached to a shaft, the third gear meshing with the first pinion and the third gear and the shaft rotating when the first intermediate gear rotates, and a steering arm coupled to the shaft, the steering arm being coupled to a steering pushrod to turn the wheels of a vehicle when the shaft rotates.

Description

AREA OF REVELATION

[0001] This disclosure relates generally to steering systems and more particularly to rotary steering systems. GENERAL STATE OF THE ART

[0002] Known vehicles typically include a mechanical linkage connecting a vehicle's front wheels to a steering wheel, allowing a driver to adjust the alignment of the front wheels by turning the steering wheel. For example, many known steering systems incorporate rack and pinion gears that convert rotary motion of a steering wheel into linear actuation or movement of a steering pushrod and / or tie rods connected to the front wheels. As the steering wheel rotates, the steering pushrod and / or tie rods change the angular orientation of the wheels, steering the vehicle.

[0003] In recent years, trucks have utilized hydraulically assisted recirculating ball (RCB) steering systems. Hydraulic assistance in RCB steering systems is provided by a pump that supplies hydraulic steering fluid to the RCB system. In some implementations, electronic torque overlay mechanisms are used to provide electric steering feel to the hydraulic system. SUMMARY

[0004] Example rotary steering systems are disclosed in this document. An example vehicle steering system includes an input gear attached to one end of an input shaft. A first idler gear is attached to a first pinion gear. The first idler gear meshes with the input gear. A second idler gear is attached to a second pinion gear. The second pinion gear meshes with one of the first idler gear and a third idler gear. A motor is attached to a third pinion gear. The third pinion gear meshes with the second idler gear. The motor is operable to rotate the first idler gear and the first pinion gear. A third gear is attached to a shaft. The third gear meshes with the first pinion gear. The third gear and the shaft are operable to rotate when the first idler gear rotates. A steering arm is coupled to the shaft.The steering arm is to be coupled to a steering push rod in order to swivel the wheels of a vehicle when the shaft rotates.

[0005] An exemplary vehicle steering system includes an input gear. A first gear assembly includes a first idler gear attached to a first pinion gear. The first idler gear meshes with the input gear. A second gear assembly includes a second idler gear attached to a second pinion gear. The second pinion gear meshes with one of the first idler gear and a third idler gear. An output shaft includes a third gear meshed with the first pinion gear. A motor is attached to a third pinion gear. The third pinion gear meshes with the second idler gear. The motor is to provide torque that rotates the input shaft, the first gear assembly, the second gear assembly, and the output shaft. A steering arm is coupled to the shaft. The steering arm is to be coupled to a steering pushrod to pivot wheels of a vehicle when the output shaft rotates.

[0006] An example device includes an input gear that includes an input gear. A first gear set includes a first idler gear and a first pinion gear. The first idler gear meshes with the input gear. A second gear set includes a second idler gear attached to a second pinion gear. The second pinion gear meshes with the first idler gear. An output shaft includes a sector gear and splines. The sector gear is positioned at a first end of the output shaft. The splines are positioned at a second end of the output shaft opposite the first end. The sector gear meshes with the ring gear. A motor is attached to a third pinion gear. The third pinion gear meshes with the second idler gear. The motor is to provide torque that rotates the input shaft, the first gear set, the second gear set, and the output shaft. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 illustrates a steering system in an engine compartment environment of a vehicle. Fig. 2A illustrates a view of an exemplary implementation of a portion of the steering system of Fig. 1. Fig. Figure 2B illustrates a view of another exemplary implementation of the portion of the steering system of Fig. 1. Fig. 3 illustrates another view of the portion of the exemplary steering system of Fig. 1, Fig. 2A and Fig. 2B. Fig. Figure 4 illustrates another view of a portion of the exemplary steering system of Fig. 1, Fig. 2A, Fig. 2B and Fig. 3. Fig. Figure 5 illustrates another view of a portion of the first exemplary steering system of Fig. 1, Fig. 2A, Fig. 2B, Fig. 3 and Fig. 4. Fig. Figure 6 illustrates another view of a portion of the first exemplary steering system of Fig. 1, Fig. 2A, Fig. 2B, Fig. 3, Fig. 4 and Fig. 5. Fig. Figure 7 illustrates another view of a portion of the first exemplary steering system of Fig. 1, Fig. 2A, Fig. 2B, Fig. 3, Fig. 4, Fig. 5 and Fig. 6. Fig. Figure 8A illustrates a view of another exemplary implementation of the portion of the steering system of Fig. 1. Fig. Figure 8B illustrates a view of another exemplary implementation of the portion of the steering system of Fig. 1. Fig. 9 is a flow diagram illustrating an exemplary method for assembling a steering system according to the teachings of this disclosure.

[0007] In general, the same reference numerals are used throughout the drawing(s) and the accompanying written description to refer to the same or similar parts. The figures are not necessarily to scale.

[0008] As used herein, unless otherwise specified, the term "above" describes the relationship of two parts relative to the ground. A first part is above a second part if the second part has at least one part between the ground and the first part. Likewise, as used herein, a first part is "below" a second part if the first part is closer to the ground than the second part. As noted above, a first part can be above or below a second part with one or more of the following elements present: with other parts therebetween, with no other parts therebetween, with the first and second parts touching, or without the first and second parts in direct contact.

[0009] As used herein, connection references (e.g., attached, coupled, connected, and joined) may imply intermediate links between the elements referred to by the connection reference and / or relative movement between those elements, unless otherwise specified. Accordingly, connection references do not necessarily imply that two elements are directly connected and / or have a fixed relationship. As used herein, the statement that any part is in "contact" with another part is defined to mean that there is no intermediate part between the two parts.

[0010] Unless expressly stated otherwise, descriptors such as "first," "second," "third," etc., are used in this specification without implying or otherwise indicating any meaning of priority, physical order, arrangement in a list, and / or order, but are used merely as labels and / or arbitrary names to distinguish elements for a better understanding of the disclosed examples. In some examples, the descriptor "first" may be used in the detailed description to refer to an element, while the same element may be referred to in a patent claim with a different descriptor such as "second" or "third." In such cases, it is understood that such descriptors are merely used to identify the elements in the context of the discussion (e.g.,within a claim) that might otherwise have the same name.

[0011] As used herein, "approximately" and "about" modify their subjects / values ​​to recognize the potential presence of variations that occur in real-world applications. For example, "approximately" and "about" may modify dimensions that may not be exact due to manufacturing tolerances and / or other real-world imperfections, as would be apparent to one of ordinary skill in the art. For example, "approximately" and "about" may indicate that such dimensions may be within a tolerance range of + / - 10%, unless otherwise noted in the description below.

[0012] As used herein in the context of describing the position and / or orientation of a first object, plane, or axis relative to a second object, the term "substantially perpendicular" includes the term perpendicular and, more broadly, includes a meaning whereby the first object, plane, or axis is positioned and / or oriented relative to the second object at an absolute angle of no more than ten degrees (10°) from parallel. For example, a first axis that is substantially perpendicular to a second axis is positioned and / or oriented relative to the second axis at an absolute angle of no more than ten degrees (10°) from perpendicular.

[0013] As used herein in the context of describing the position and / or orientation of a first object, plane, or axis relative to a second object, the term "substantially parallel" includes the term parallel and, more broadly, includes a meaning whereby the first object, plane, or axis is positioned and / or aligned relative to the second object at an absolute angle of no more than ten degrees (10°) from parallel. For example, a first axis that is substantially parallel to a second axis is positioned and / or aligned relative to the second axis at an absolute angle of no more than ten degrees (10°) from parallel.Accordingly, as used herein, the term “non-parallel” includes the first object, plane, or axis not being parallel to the second object, plane, or axis within ten degrees (10°).

[0014] As used herein, the term "in communication," including variations thereof, includes direct communication and / or indirect communication through one or more intervening components and does not require direct physical (e.g., wired) communication and / or constant communication, but rather additionally includes selective communication at periodic intervals, scheduled intervals, aperiodic intervals, and / or on one-time events.

[0015] As used herein, a "programmable circuit" is defined as including (i) one or more special-purpose electrical circuits (e.g., an application-specific integrated circuit (ASIC)) configured to perform a specific operation(s) and including one or more semiconductor-based logic devices (e.g., electrical hardware implemented by one or more transistors) and / or (ii) one or more general-purpose semiconductor-based electrical circuits programmable with instructions to perform a specific function(s) and / or operation(s) and including one or more semiconductor-based logic devices (e.g., electrical hardware implemented by one or more transistors). Examples of programmable circuits are programmable microprocessors such as central processing units (CPUs) that can execute first instructions,to perform one or more operations and / or functions, field-programmable gate arrays (FPGAs) that can be programmed with second instructions to cause the configuration and / or structuring of the FPGAs to perform one or more operations and / or functions according to the first instructions, graphics processing units (GPUs) that can execute first instructions to perform one or more operations and / or functions, digital signal processors (DSPs) that can execute first instructions to perform one or more operations and / or functions, XPUs, network processing units (NPUs), one or more microcontrollers that can execute first instructions to perform one or more operations and / or functions, and / or integrated circuits such as application-specific integrated circuits (ASICs). For example, an XPU can be implemented by a heterogeneous computing system,which includes multiple types of programmable circuits (e.g., one or more FPGAs, one or more CPUs, one or more GPUs, one or more NPUs, one or more DSPs, etc. and / or any combination thereof) and orchestration technology (e.g., application programming interface(s) (API(s)) that can assign the computational task(s) to the one or more types of programmable circuits suitable and available to perform the computational task(s).

[0016] As used herein, an integrated circuit / circuitry is defined as one or more semiconductor packages containing one or more circuit elements, such as transistors, capacitors, inductors, resistors, current paths, diodes, etc. For example, an integrated circuit may be implemented as one or more of an ASIC, an FPGA, a chip, a microchip, a programmable circuit, a semiconductor substrate coupling multiple circuit elements, a system-on-chip (SoC), etc. DETAILED DESCRIPTION

[0017] Exemplary rotary steering systems are disclosed in this document. Conventionally, some heavy-duty trucks have utilized a steering mechanism that includes hydraulically assisted RCB gearboxes or worm gears and wheel steering gears. In some cases, a pump provides hydraulic assistance to the RCB gearbox by pumping hydraulic steering fluid through the steering system. In some such cases, a steering shaft rotates when the steering wheel is turned to cause a ball nut of the RCB gearbox to move linearly. The ball nut, in turn, rotates a gear segment coupled to a steering arm that pivots the wheels. The hydraulic steering fluid is pumped to assist the movement of the ball nut based on the rotation of the steering shaft. Alternatively, an electrically driven motor can be used instead of the hydraulic pump to move the ball nut.However, space in a vehicle's engine compartment environment must be kept clear of other vehicle systems and reserved for the linear movement of the ball nut in RCB steering gears.

[0018] Examples disclosed herein provide fully rotary steering gear systems that generate sufficient power to steer relatively heavy vehicles, such as trucks. Thus, the steering systems enable such relatively heavy vehicles to utilize electrically powered steering systems instead of hydraulically powered steering systems. Furthermore, a lack of linear motion in the rotary steering gear systems allows the systems to occupy less space in an engine compartment environment of the vehicle, thus leaving more space in the engine compartment environment for other systems associated with the vehicle, such as an internal combustion engine, a cooling fan, etc. Additionally, the rotary steering gear system can be implemented in a variety of vehicles with different engine compartment layouts.Non-limiting examples of vehicles disclosed in this document include internal combustion vehicles, battery electric vehicles, hybrid electric vehicles, fuel cell vehicles, etc. Although the fully rotary steering gears disclosed in this document generate sufficient power to steer trucks, the examples disclosed in this document may be implemented in any other steerable vehicle.

[0019] Fig. 1 illustrates a first view of a vehicle steering system (e.g., a steering device, a steering actuator) 102 in an engine compartment environment 100 of a vehicle. In Fig. 1, the steering system 102 is positioned within a housing 104. In some examples, the housing 104 includes one or more housings coupled to protect the steering system 102. In some examples, an input shaft 106 of the steering system 102 protrudes from the housing 104. In some examples, the input shaft 106 is coupled to a steering shaft 108 via a connection 110. In some examples, the steering shaft 108 is operatively coupled to a steering wheel of the vehicle. As a result, the input shaft 106 rotates with the steering shaft 108 when a driver turns the steering wheel. The steering system 102, in turn, converts the rotation of the steering wheel into rotation of the vehicle's wheels to steer the vehicle. Additionally or alternatively, the steering system 102 may cause the vehicle's wheels to rotate without the rotation of the steering wheel when the vehicle is driven autonomously.

[0020] In Fig. 1, the steering system 102 is positioned in the engine compartment environment 100 between a frame 112 and a fan 114 of the vehicle. Typically, vehicles include the fan 114 to direct air through a radiator and maintain an operating temperature of an internal combustion engine of the vehicle. Accordingly, the fan 114, the radiator, and the internal combustion engine occupy a significant portion of the space in the engine compartment environment 100. The internal combustion engine of the vehicle is Fig. 1 to more clearly illustrate an output shaft 116, a steering arm 118, and a steering pushrod 120 of the steering system 102. Advantageously, stacked gears and a position of a motor 122 of the steering system 102 allow the steering system 102 to be positioned in relatively small spaces within the engine compartment environment 100 while still generating sufficient power to turn the wheels of heavy trucks. In particular, the stacked gears provide a combined gear reduction of greater than 100:1 to generate sufficient power to turn the wheels in.

[0021] The output shaft 116 extends from a gear segment within the housing 104. More specifically, the output shaft 116 protrudes from a lower portion of the housing 104 to couple to the steering arm 118. In some examples, an opening of the steering arm 118 includes splines that mate with splines 124 of the output shaft 116. Further, the steering arm 118 is coupled to the steering pushrod 120, which is connected to a wheel of the vehicle.

[0022] In Fig. 1, the steering system 102 causes the output shaft 116 to rotate in response to rotation of the steering shaft 108 and / or an autonomous steering command. The output shaft 116, in turn, moves (e.g., pivots) the steering arm 118. Further, the steering arm 118 converts the rotation of the output shaft 116 into linear movement of the steering push rod 120. In some examples, the steering push rod 120 is connected to a steering knuckle of a wheel of the vehicle. In some such examples, the linear movement of the steering push rod 120 adjusts an orientation of the steering knuckle to turn the wheels. As a result, the steering system 102 converts the rotation of the steering shaft 108 into movement of the wheels to steer the vehicle.

[0023] In some examples, a sufficient amount of power must be generated to turn the wheels of heavier vehicles, such as trucks. Thus, the steering system 102 provides a combined reduction ratio of greater than 100:1 to generate the sufficient amount of power required to steer trucks while utilizing an electrically powered steering system.

[0024] Fig. 2A illustrates a portion of a first exemplary steering system 200 (e.g., a first exemplary implementation of the steering system 102 of Fig. 1). In Fig. 2A, the steering system 102 includes an input shaft 201 (e.g., a first exemplary implementation of the input shaft 106 from Fig. 1) and an input gear 202 attached to the input shaft 201. The steering system 200 also includes a first gear assembly 204 (e.g., a first torque multiplying assembly, a first gear set), a second gear assembly 206 (e.g., a second torque multiplying assembly, a second gear set), the output shaft 116, the motor 122 of Fig. 1 and a first pinion 210 attached to a shaft 211 of the motor 122. The first gear assembly 204 includes a first idler gear 212 and a second pinion 214. A second gear assembly 206 includes a second idler gear 216 and a third pinion 218.

[0025] In the illustrated example from Fig. 2A, the output shaft 116 includes a gear segment 220 attached to a first longitudinal end 222 of the output shaft 116. The output shaft 116 also includes the splines 124 positioned at a second longitudinal end 224 of the output shaft 116. The first longitudinal end 222 of the output shaft 116 faces in a first direction (e.g., upward) and the second longitudinal end 224 of the output shaft 116 faces in a second direction (e.g., downward) opposite the first direction. The gear segment 220 faces at least partially in the first direction (e.g., a same direction as the first longitudinal end 222, upward in the orientation of Fig. 2A).

[0026] In the illustrated example from Fig. 2A, the input gear 202 and the third pinion gear 218 mesh with the first idler gear 212. The first pinion gear 210 meshes with the second idler gear 216. The second pinion gear 214 meshes with the sector gear 220. The motor 122 provides assist steering torque when the input shaft 201 rotates and / or provides total steering torque when the associated vehicle is traveling autonomously. In particular, the motor 122 rotates the first pinion gear 210, which rotates the second idler gear 216 and, in turn, the third pinion gear 218. Furthermore, the third pinion 218 and / or the input gear 202 rotate the first intermediate gear 212 and in turn the second pinion 214. Furthermore, the second pinion 214 rotates the toothed segment 220. The serrations 124 rotate with the toothed segment 220 and pivot the steering arm 118 from Fig. 1, which is the steering push rod 120 from Fig. 1 moves and causes the vehicle's wheels to pivot.

[0027] In the illustrated example from Fig. 2A, the first gear assembly 204 and the second gear assembly 206 increase the torque generated by the motor 122 to produce sufficient force to rotate the sector gear 220 when the steering system 200 is implemented in a heavier vehicle. In particular, because the first pinion gear 210 has a smaller circumference and fewer teeth (e.g., gears) than the second idler gear 216, the engagement between the first pinion gear 210 and the second idler gear 216 provides a first reduction ratio. Similarly, the engagement between the third pinion gear 218 and the first idler gear 212 provides a second reduction ratio, and the engagement between the second pinion gear 214 and the sector gear 220 may provide a third reduction ratio. Together, the reduction gears can provide a reduction ratio of greater than 100:1 to increase the torque that the gear segment 220 receives from the second pinion 214.

[0028] In the illustrated example from Fig. 2A, the input shaft 201 and the input gear 202 are aligned along a first rotational axis 226. The first idler gear 212 and the second pinion gear 214 are aligned along a second rotational axis 228. The second idler gear 216 and the third pinion gear 218 are aligned along a third rotational axis 230. The first pinion gear 210 and the shaft 211 of the motor 122 are aligned along a fourth rotational axis 232. In the illustrated example of Fig. 2A, the first rotational axis 226, the second rotational axis 228, the third rotational axis 230, and the fourth rotational axis 232 are substantially parallel. In some examples, at least two of the first, second, third, and / or fourth rotational axes 226, 228, 230, 232 are not parallel to each other. For example, the third rotational axis 230 may not be parallel to the second rotational axis 228 while the third pinion gear 218 is operatively engaged with the first idler gear 212.

[0029] In the illustrated example from Fig. 2A, the output shaft 116 (e.g., the sector gear 220 and the splines 124) is aligned along a fifth rotational axis 234. In some examples, the fifth rotational axis 234 is substantially perpendicular to the first rotational axis 226, the second rotational axis 228, the third rotational axis 230, and the fourth rotational axis 232. In particular, the second pinion gear 214 and the sector gear 220 are bevel gears, and the fifth rotational axis 234 intersects the second rotational axis 228. Accordingly, the engagement between the second pinion gear 214 and the sector gear 220 converts rotations within the system 200 from rotations along axes transverse to the output shaft 116 to rotation along a longitudinal axis (e.g., the fifth rotational axis 234) of the output shaft 116. Thus, the conversion of the direction of rotation provided by the engagement between the second pinion 214 and the gear segment 220 allows the steering system 200 to operate without linear motion.Advantageously, the lack of linear movement during operation allows the steering system 200 to occupy less space and thus fit into a variety of engine compartment environments, while leaving additional space for other systems associated with the vehicle.

[0030] In the illustrated example from Fig. 2A, the input gear 202 and the third pinion 218 mesh with the first intermediate gear 212 on a first geometric plane 236. The first pinion 210 meshes with the second intermediate gear 216 on a second geometric plane 238. Furthermore, the second pinion 214 and a portion of the gear segment 220 that meshes with the second pinion 214 are aligned on the second geometric plane 238. In the illustrated example of Fig. As shown in Figure 2A, the first and second geometric planes 236, 238 are substantially parallel. Furthermore, the gear segment 220 rotates within a third geometric plane 240 that is substantially perpendicular to the first and second geometric planes 236, 238.

[0031] In some examples, the second pinion gear 214 and the portion of the sector gear 220 are aligned in a different geometric plane (e.g., a fourth geometric plane substantially parallel to the first and second geometric planes) that lies between the first geometric plane 236 and the second geometric plane 238. In some examples, the first pinion gear 210 and the second idler gear 216 are positioned on the side of the first idler gear 212 opposite the second pinion gear 214 to fit certain engine compartment environments. In such examples, the first pinion gear 210 engages the second idler gear 216 on a first side of the first geometric plane 236, and the second pinion gear 214 engages the sector gear 220 on a second side of the first geometric plane 236 opposite the first side.Additionally, a position of the first rotation axis 226 is orbital relative to the second rotation axis 228; a position of the third rotation axis 230 is orbital relative to the second rotation axis 228; and a position of the fourth rotation axis 232 is orbital relative to the third rotation axis 230. Thus, the steering not only occupies relatively little space but is also adaptable based on the specific engine compartment environment in which the steering system 200 is to be implemented.

[0032] In the illustrated example from Fig. 2A, the steering system 200 includes a cover 242 (e.g., a partial housing) positioned around the output shaft 116 between the gear segment 220 and the splines 124. In particular, the cover 242 includes a first end 245 proximate the gear segment 220 and a second end 247 proximate the splines 124. In some examples, the cover 242 is connected to the housing 104 of Fig. 1. In some examples, the cover 242 includes a rim 249 (e.g., a protruding edge) extending from the fifth rotation axis 234 at the first end 245. In such examples, the rim 249 is positioned below the sector gear 220. In some examples, the rim 249 extends completely around the first end 245 of the cover 242. In some other examples, the rim 249 extends around a portion of the first end 245 of the cover 242 that corresponds to a range of motion of the sector gear 220. In some examples, the sector gear 220 slides on the rim 249 as the second pinion rotates the sector gear 220. In such examples, the rim 249 provides axial support to the sector gear 220.

[0033] To enable the first gear assembly 204 and the output shaft 116 to be supported, the steering system 200 includes a first axial position screw 244 (e.g., a first positioning screw, a first engagement screw, a first axial position adjustment screw, etc.) and a second axial position screw 246 (e.g., a second positioning screw, a second engagement screw, a second axial adjustment screw, etc.). The first axial position screw 244 is positioned along the second rotational axis 228, and the second axial position screw 246 is positioned along the fifth rotational axis 234. The steering system 200 also includes a first retaining ring 248 (e.g., a first thread locking ring) and a second retaining ring 250 (e.g., a second thread locking ring) to couple the first axial positioning screw 244 and the second axial positioning screw 246 to the first gear assembly 204 and the output shaft 116, respectively.

[0034] As discussed in more detail below, during assembly of the steering system 200, the first axial positioning screw 244 and the second axial positioning screw 246 move the first gear assembly 204 and the output shaft 116, respectively, until engagement between the second pinion gear 214 and the sector gear 220 provides a specific torque (e.g., 1 Newton meter (Nm)) as the second pinion gear 214 rotates, thereby forming a precise spline between the second pinion gear 214 and the sector gear 220. In some examples, the first axial positioning screw 244 and / or the second axial positioning screw 246 are coupled to the housing 104 or a sub-housing when the respective positions of the first gear assembly 204 and the output shaft 116 are adjusted. For example, the first axial positioning screw 244 and / or the second axial positioning screw 246 may be caulked to the housing 104 or the sub-housing.In some examples, the first axial positioning screw 244 and / or the second axial positioning screw 246 may be secured with a locknut. As a result, the first axial positioning screw 244 and the second axial positioning screw 246 support the first gear assembly 204 and the output shaft 116 within the housing 104.

[0035] To enable the second gear assembly 206 to be supported, the second gear assembly 206 includes a first journal 252, a second journal 254, and a third journal 256. The first journal 252 is positioned on a side of the third pinion 218 opposite the second idler gear 216. Additionally or alternatively, the first journal 252 may be positioned within a circumference of the third pinion 218. The second journal 254 is positioned between the third pinion 218 and the second idler gear 216. Further, the third journal 256 is positioned on a side of the second idler gear 216 opposite the third pinion 218. Additionally or alternatively, the third journal 256 may be positioned within a circumference of the second idler gear 216.The bearing journals 252, 254, 256 may be positioned in respective sleeves or shells coupled to the housing 104 or other sub-housing to support them while the second gear assembly 206 can rotate.

[0036] Fig. 2B illustrates another exemplary steering system 260 that includes one or more additional idler gears 262 in addition to the components of the steering system 200 of Fig. 2A. In the illustrated example from Fig. 2B, the additional idler gear set(s) 262 include one or more idler gears, each attached to a corresponding pinion gear (e.g., similar to the second idler gear 216 and the third pinion gear 218 of the second gear assembly 206). Thus, the idler gear set(s) 262 include an idler gear meshing with the first pinion gear 210 at one end and a pinion gear meshing with the second idler gear 216 at the other end to increase the reduction ratio and thus the torque delivered to the sector gear 220.

[0037] In the illustrated example from Fig. 2B, in operation, the motor 122 rotates the first pinion gear 210, which rotates an idler gear of the idler gear set(s) 262 that meshes with the first pinion gear 210. Accordingly, a pinion gear of the idler gear set(s) 262 that is attached to the idler gear of the idler gear set(s) 262 also rotates. In some examples, the pinion gear meshes with and rotates the second idler gear 216 and in turn the third pinion gear 218. As a result, the first idler gear 212, the second pinion gear 214, the sector gear 220, and the splines 124 rotate. In some examples, the pinion gear of the idler gear set(s) 262 rotates another idler gear of the idler gear set(s) 262 and another pinion gear attached thereto. The pinion can in turn engage with and rotate the second intermediate gear 216 or another intermediate gear set.The quantity of intermediate gears and associated pinions included in the additional intermediate gear set(s) 262 between the first pinion gear 210 and the second intermediate gear 216 depends on the vehicle in which the steering system 260 is to be implemented and / or the space available for the steering system 260 in the engine compartment environment of the vehicle.

[0038] Fig. 3 shows a further view of the exemplary steering systems 200, 260 from Fig. 2A-2B, in which a portion of the cover 242 has been removed. In the illustrated example of Fig. 3, the steering system 200 includes a first roller bearing 302 (e.g., a first needle bearing), a second roller bearing 304 (e.g., a second needle bearing), and a spring 306 positioned around the output shaft 116 between the cover 242 and the output shaft 116. Specifically, the first roller bearing 302 is positioned at the first end 245 of the cover 242; the second roller bearing 304 is positioned at the second end 247 of the cover 242; and the spring 306 is positioned around a portion of the output shaft 116 between the first roller bearing 302 and the second roller bearing 304.

[0039] In the illustrated example from Fig. 3, the first roller bearing 302 and the second roller bearing 304 include inner radial surfaces (not shown) coupled to an outer radial surface 308 of the output shaft 116. The first roller bearing 302 and the second roller bearing 304 also have outer radial surfaces 310 coupled to an inner radial surface 312 of the cover 242. The first roller bearing 302 and the second roller bearing 304 also include roller bearings (e.g., rolling elements) (not shown) positioned between the inner and outer radial surfaces 310 of the roller bearings 302, 304. During operation, as the second pinion gear 214 rotates the sector gear 220, the roller bearings roll between the inner radial surfaces and the outer radial surfaces 310 to radially support the output shaft 116. Thus, the second axial positioning screw 246 and / or the cover 242 can axially support the output shaft 116, and the roller bearings 302, 304 can radially support the output shaft 116.

[0040] In the illustrated example from Fig. 3, the spring 306 provides a constant force on the output shaft 116 in a direction toward the sector gear 220 (e.g., upward) during assembly of the steering system 200. In particular, the inner radial surface 312 of the cover 242 includes a first recess 314, and a first end of the spring 306 (e.g., an end opposite the sector gear 220) may be positioned on a surface 315 (e.g., a shoulder) of the first recess 314 facing the first end 245. Furthermore, the outer radial surface 308 of the output shaft 116 includes a projection (not shown) (e.g., a second shoulder) against which a second end of the spring 306 exerts the upward force. For example, the projection against which the second end of the spring 306 is positioned may be defined at or below an end of the first roller bearing 302 facing the second longitudinal end 224 of the output shaft 116.Furthermore, a surface of the projection that contacts the spring 306 faces the second longitudinal end 224. As a result, the spring 306 urges the sector gear 220 against the second pinion gear 214 to help move the output shaft 116 into a position that results in a desired torque between the second pinion gear 214 and the sector gear 220 during assembly. In some examples, the spring 306 is removed when the second axial positioning screw 246 and / or the cover 242 are removed from the housing 104. Fig. 1. In some examples, an actuator and associated programmable circuitry are used instead of spring 306 to provide the upward force during assembly. For example, the programmable circuitry may cause the actuator to move the output shaft 116 toward the second pinion gear 214 and stop movement of the output shaft 116 when the programmable circuitry determines that the actuator encounters resistance indicating sufficient contact between the second pinion gear 214 and the sector gear 220.

[0041] In some examples, the inner radial surface 312 of the cover 242 includes a second recess 316 for the first roller bearing 302 and a third recess 318 for the second roller bearing 304. Additionally, the outer radial surface 308 of the output shaft 116 may include a second protrusion 320 against which one end of the first roller bearing 302 is positioned. Similarly, the outer radial surface 308 of the output shaft 116 may include a third protrusion 322 at the first longitudinal end 222 that the second roller bearing 304 contacts. Accordingly, the recesses 316, 318 in the cover 242 and the projections 320, 322 of the output shaft 116 serve as position markers for the roller bearings 302, 304 to improve an accuracy of the positions of the roller bearings 302, 304 and / or an efficiency with which the roller bearings 302, 304 are positioned during assembly of the steering system 200.

[0042] Fig. 4 illustrates another view of the first exemplary steering system 200 of Fig. 2 and Fig. 3. In the Fig. 4, the input gear 202 and the third pinion 218 mesh with the first intermediate gear 212 within the first geometric plane 236. The first pinion 210 meshes with the second intermediate gear 216 within the second geometric plane 238. In addition, the second pinion 214 meshes with the toothed segment 220 within the second geometric plane 238. In the illustrated example from Fig. 4, the second axial positioning screw 246 and the second retaining ring 250 extend from the first longitudinal end 222 of the output shaft 116.

[0043] Fig. 5 illustrates an enlarged view of the second axial positioning screw 246 and the second retaining ring 250, which position the output shaft 116 of the steering system 200 during assembly. As in the illustrated example of Fig. 5, the second axial positioning screw 246 extends at least partially through a pocket 502 in the output shaft 116. In particular, the pocket 502 extends at least partially through the output shaft 116 along the fifth rotational axis 234. The second retaining ring 250 holds the second axial positioning screw 246 in the recess 502. For example, the second retaining ring 250 may be a jam nut that locks the second axial positioning screw 246 in the pocket 502 of the output shaft 116. Thus, the second retaining ring 250 allows the output shaft 116 to be axially movable with the second axial positioning screw 246. In some examples, the steering system 200 includes a washer 504 positioned in the pocket 502 and in contact with the second retaining ring 250.In such examples, the washer 504 facilitates the rotational movement of the second axial positioning screw 246 and / or the second retaining ring 250.

[0044] Fig. 6 illustrates another view of the first steering system 200 from Fig. 2-5. In the illustrated example from Fig. 6, the input shaft 201 and the input gear 202 are aligned along the first rotational axis 226. The first intermediate gear 212 and the second pinion 214 are aligned along the second rotational axis 228. The second intermediate gear 216 and the third pinion 218 are aligned along the third rotational axis 230. The first pinion 210 and the shaft 211 of the motor 122 are aligned along the fourth rotational axis 232. In the illustrated example of Fig. 6, the first axial positioning screw 244 and the first retaining ring 248 extend from one side of the first gear assembly 204 to an opposite side of the first idler gear 212 from the second pinion 214.

[0045] Fig. 7 illustrates an enlarged view of the first axial positioning screw 244 and the first retaining ring 248, which position the first gear assembly 204 of the steering system 200 during assembly and / or support the first gear assembly 204 during operation. As in the illustrated example in Fig. 7, the first axial positioning screw 244 extends at least partially through a pocket 702 in the first output shaft 204. In particular, the pocket 702 extends at least partially through the first gear assembly 204 along the second rotational axis 228. The first retaining ring 248 holds the first axial positioning screw 244 in the recess 702. For example, the first retaining ring 248 may be a jam nut that locks the first axial positioning screw 244 in the recess 702 of the first gear assembly 204. Thus, the first retaining ring 248 allows the first gear assembly 204 to be axially movable with the first axial positioning screw 244. In some examples, the steering system 200 includes washers 704, 706 positioned in the pocket 702.For example, a first washer 704 may contact the first retaining ring 248, and a second washer 706 may contact an inner surface of the first gear assembly 204. In such examples, the washers 704, 706 facilitate rotational movement of the first axial positioning screw 244 and / or the first retaining ring 248.

[0046] Fig. 8A illustrates a portion of a first exemplary steering system 800 (e.g., a second exemplary implementation of the steering system 102 of Fig. 1). In the illustrated example from Fig. 8A, the steering system 800 includes an input shaft 801 (e.g., a second exemplary implementation of the input shaft 106 of Fig. 1). The steering system 800 further includes an input gear 802 and a first intermediate gear 804 attached to the input shaft 801. In particular, the input shaft 801 includes a first end 806 (e.g., an end that connects to the steering shaft 108 of Fig. 1) and a second end 808 opposite the first end. The input gear 802 is attached to the second end 808.

[0047] In the illustrated example from Fig. 8A, the steering system 800 further includes a first gear assembly 810 (e.g., a first gear set), a second gear assembly 812 (e.g., a second gear set), the output shaft 116, the electric motor 122, an electric motor shaft 811, and a first pinion gear 814 attached to one end of the motor shaft 811. The first gear assembly 810 includes a second idler gear 816 and a second pinion gear 818. The second gear assembly 812 includes a third idler gear 820 and a third pinion gear 822. The first pinion gear 814 meshes with the second idler gear 816, providing a first reduction gear. The second pinion gear 818 meshes with the first idler gear 814, providing a second reduction gear. The input gear 802 meshes with the third intermediate gear 820, providing a third reduction ratio. The third pinion gear 822 meshes with the gear segment 220, providing a fourth reduction ratio.

[0048] During operation, the motor 122 rotates the first pinion 814, which in turn rotates the second intermediate gear 816 and the second pinion 818. The second pinion 818 rotates the first intermediate gear 804 and thus transmits the torque generated by the motor 122 to the input shaft 801. The transmitted torque enables the input gear 802 to rotate the third intermediate gear 820 and in turn the third pinion 822. Thus, the third pinion 822 rotates the toothed segment 220 and the splines 124 from Fig. 1-3 rotate with the toothed segment 220 and swing the steering arm 118 out Fig. 1, whereby the steering push rod 120 from Fig. 1 is moved and causes the vehicle's wheels to pivot.

[0049] In the illustrated example from Fig. 8A, the input shaft 801 is along a first rotational axis 824 (e.g., the first rotational axis 226 of Fig. 2A). Thus, the input gear 802 and the first intermediate gear 804 rotate about the first rotation axis 824. In Fig. 8A, the first idler gear 804 is positioned on a projection 826 in the input shaft 801 that extends radially outward between the first end 806 and the second end 808. Thus, the first idler gear 804 includes a larger circumference than the input gear 802.

[0050] In the illustrated example from Fig. 8A, the first gear assembly 810 is aligned along a second rotational axis 828. Thus, the second idler gear 816 and the second pinion 818 rotate about the second rotational axis 828. In Fig. 8A, the second rotational axis 828 is substantially perpendicular to the first rotational axis 824. Thus, the first idler gear 804 and the second pinion gear 818 form a first set of bevel gears in the steering system 800. In the illustrated example of Fig. 8A, the second rotational axis 828 is rotating relative to the first rotational axis 824 as long as the second pinion 818 is engaged with the first idler gear 804 and the second idler gear 816 is engaged with the first pinion 814.

[0051] In the illustrated example from Fig. 8A, the motor shaft 811 is aligned along a third rotational axis 830, and consequently, the first pinion gear 814 is rotatable about the third rotational axis 830. The third rotational axis 830 is substantially perpendicular to the second rotational axis 828. Thus, the first pinion gear 814 and the second idler gear 816 form a second set of bevel gears in the steering system 800.

[0052] In the illustrated example from Fig. 8A, the second gear assembly 812 is aligned along a fourth rotational axis 832. Accordingly, the third idler gear 820 and the third pinion 822 are rotatable about the fourth rotational axis 832. In Fig. 8A, the fourth rotational axis 832 is substantially perpendicular to the first rotational axis 824. Thus, the input gear 802 and the third idler gear 820 form a third set of bevel gears in the steering system 800. In some examples, the fourth rotational axis 832 is also substantially perpendicular to the second rotational axis 828. The fifth rotational axis 234 of the output shaft 116 is substantially perpendicular to the fourth rotational axis 832, such that the third pinion gear 822 and the sector gear 220 form a fourth set of bevel gears in the steering system 800. In some examples, the steering system 800 includes axial positioning screws (e.g., the first axial positioning screw 244 of the Fig. 2-4 and 6-7, the second axial positioning screw 246 from the Fig. 2-5) to support the first gear 810, the second gear assembly 812, and the output shaft 116.

[0053] Fig. 8B illustrates another exemplary steering system 860 that includes one or more additional idler gears 862 in addition to the components of the steering system 800 of Fig. 8A. In the illustrated example from Fig. 8B, the additional intermediate gear set(s) 862 include(s) one or more intermediate gears, each attached to a corresponding pinion (e.g., similar to the second intermediate gear 216 and the third pinion 218 of the second gear assembly 206) ( Fig. 2A-2B). Thus, the idler gear set(s) 862 include an idler gear meshing with the first pinion gear 814 at one end and another pinion gear meshing with the second idler gear 816 at the other end to increase the reduction ratio and thus the torque supplied to the sector gear 220.

[0054] Accordingly, in operation, the motor 122 rotates the first pinion gear 814, which rotates an idler gear of the idler gear set(s) 862 that meshes with the first pinion gear 814. In some examples, a pinion gear of the idler gear set(s) 862 that is attached to the idler gear of the idler gear set(s) 862 is connected to and rotates the second idler gear 816 and thus the second pinion gear 818. As a result, the first idler gear 804, the input gear 802, the third idler gear 820, the third pinion gear 822, the sector gear 220, and the splines 124 rotate. In some examples, the pinion gear of the idler gear set(s) 862 that is attached to the idler gear that meshes with the first pinion gear 814 rotates another idler gear and yet another pinion gear attached thereto. The pinion can in turn mesh with the second intermediate gear 816 or another intermediate gear set.The quantity of intermediate gears and associated pinions included in the additional intermediate gear set(s) 862 between the first pinion gear 814 and the second intermediate gear 816 depends on the vehicle in which the steering system 860 is to be implemented and / or the space available for the steering system 860 in the engine compartment environment of the vehicle.

[0055] A flowchart illustrating exemplary machine-readable instructions that can be executed by programmable circuits and / or operations that can be performed by a human to assemble the steering systems 200, 800 is shown in Fig. 9. In some examples, the machine-readable instructions cause an operation, task, etc., to be performed and / or performed in an automated manner in the real world. In this context, "automated" means without human intervention.

[0056] The program may be embodied in instructions (e.g., software and / or firmware) stored on one or more non-transitory, computer-readable and / or machine-readable storage media, such as a cache memory, magnetic storage (e.g., floppy disk, hard disk (HDD), etc.), optical storage (e.g., Blu-ray disk, compact disk (CD), digital versatile disk (DVD), etc.), a Blu-ray disk, compact disk (CD), digital versatile disk (DVD), etc.), a redundant array of independent disks (RAID), a register, a ROM, a solid-state drive (SSD), an SSD memory, non-volatile memory (e.g., electrically erasable programmable read-only memory (EEPROM), flash memory, etc.), volatile memory (e.g., random access memory (RAM) of any type, etc.), and / or another storage device or disk.The instructions of the non-transitory computer-readable and / or machine-readable medium may be programmed and / or executed by programmable circuitry residing in one or more hardware devices, but the entire program and / or portions thereof may alternatively be executed and / or instantiated by one or more hardware devices that are different from the programmable circuitry and / or embodied in specialized hardware. The machine-readable instructions may be distributed across multiple hardware devices and / or executed by two or more hardware devices (e.g., a server and a client hardware device). For example, the client hardware device may be implemented by an endpoint client hardware device (e.g., a hardware device associated with a human and / or machine user) or an intermediate client hardware device gateway (e.g.,a radio access network (RAN) gateway that can enable communication between a server and an endpoint client hardware device). Likewise, the non-transitory computer-readable storage media can include one or more media. Although the example program is described with reference to the system described in . Fig. 9, many other methods for assembling the example steering systems 200, 800 may alternatively be used. For example, the order of execution of the blocks of the flowchart(s) may be changed and / or some of the described blocks may be changed, eliminated, or combined. Additionally or alternatively, any or all of the blocks of the flowchart may be implemented by one or more hardware circuits (e.g., processor circuitry, discrete and / or integrated analog and / or digital circuits, an FPGA, an ASIC, a comparator, an operational amplifier (op amp), a logic circuit, etc.) configured to perform the corresponding operation without executing software or firmware. The programmable circuits may be deployed to various network locations and / or locally on one or more hardware devices (e.g.,a single-core processor (e.g., a single-core CPU), a multi-core processor (e.g., a multi-core CPU, an XPU, etc.). The programmable circuits may, for example, be a CPU and / or an FPGA residing in the same package (e.g., in the same IC package or in two or more separate packages), one or more processors in a single machine, multiple processors distributed across multiple servers in a server rack, multiple processors distributed across one or more server racks, etc., and / or any combination thereof.

[0057] The machine-readable instructions described in this document may be stored in one or more of a compressed format, an encrypted format, a fragmented format, a compiled format, an executable format, a packed format, etc. Machine-readable instructions as described in this document may be stored as data or a data structure (e.g., computer-readable data, machine-readable data, one or more bits (e.g., one or more computer-readable bits, one or more machine-readable bits, etc.), a bit stream (e.g., a computer-readable bit stream, a machine-readable bit stream, etc.), or a data structure (e.g., as sections of instructions, code, representations of code, etc.) that can be used to create, manufacture, and / or generate machine-executable instructions.For example, the machine-readable instructions may be fragmented and stored on one or more storage devices, disks, and / or computing devices (e.g., servers) located at the same or different locations of a network or collection of networks (e.g., in the cloud, on edge devices, etc.). The machine-readable instructions may require one or more of installation, modification, adaptation, updating, combining, amending, configuring, decrypting, decompressing, unpacking, distributing, reassigning, assembling, etc., to make them directly readable, interpretable, and / or executable by a computing device and / or other machine.For example, the machine-readable instructions may be stored in multiple pieces that are individually compressed, encrypted, and / or stored on separate computing devices, which pieces, when decrypted, decompressed, and / or combined, form a set of computer-executable and / or machine-executable instructions that implement one or more functions and / or operations that together may form a program, such as the one described herein.

[0058] In another example, the machine-readable instructions may be stored in a state where they can be read by processor circuitry, but may require the addition of a library (e.g., a dynamic link library (DLL)), a software development kit (SDK), an application programming interface (API), etc., to execute the machine-readable instructions on a particular computing device or other device. In another example, the machine-readable instructions may need to be configured (e.g., settings saved, data entered, network addresses recorded, etc.) before the machine-readable instructions and / or the corresponding program(s) can be executed, in whole or in part.As used herein, the machine-readable, computer-readable and / or machine-readable media may thus contain instructions and / or a program(s) regardless of the particular format or state of the machine-readable instructions and / or program(s).

[0059] The machine-readable instructions described in this document may be represented by any past, present, or future instruction language, scripting language, programming language, etc. For example, the machine-readable instructions may be represented using any of the following languages: C, C++, Java, C#, Perl, Python, JavaScript, HyperText Markup Language (HTML), Structured Query Language (SQL), Swift, etc.

[0060] As mentioned above, the example operations from Fig. 9 may be implemented using executable instructions (e.g., computer-readable and / or machine-readable instructions) stored on one or more non-transitory computer-readable and / or machine-readable media. As used herein, the terms non-transitory computer-readable medium, non-transitory computer-readable storage medium, non-transitory machine-readable medium, and / or non-transitory machine-readable storage medium are expressly defined to include any type of computer-readable storage device and / or storage disk and exclude propagating signals and exclude transmission media.Examples of such a non-transitory computer-readable medium, non-transitory computer-readable storage medium, non-transitory machine-readable medium, and / or non-transitory machine-readable storage medium include optical storage devices, magnetic storage devices, an HDD, a flash memory, a read-only memory (ROM), a CD, a DVD, a buffer memory, a RAM of any type, a register, and / or any other storage device or disk in which information is stored for any duration (e.g., for extended periods of time, permanently, for short periods of time, for temporarily buffering, and / or for caching the information).As used herein, the terms "non-transitory computer-readable storage device" and "non-transitory machine-readable storage device" are defined to include any physical (mechanical, magnetic, and / or electrical) hardware for storing information for a period of time, but exclude the propagation of signals and exclude transmission media.Examples of non-transitory computer-readable storage devices and non-transitory machine-readable storage devices include random access memory of any type, read-only memory of any type, solid-state memory, flash memory, optical disks, magnetic disks, disk drives, and / or redundant array of independent disks (RAID) systems. As used herein, the term “device” refers to a physical structure, such as mechanical and / or electrical equipment, hardware, and / or circuitry, that may or may not be configured by computer-readable instructions, machine-readable instructions, etc., and / or is manufactured to execute computer-readable instructions, machine-readable instructions, etc.

[0061] "Including" and "comprising" (and all forms and tenses thereof) are used in this specification as open-ended expressions. Thus, when any form of "include" or "comprising" (e.g., comprises, includes, comprising, including, having, etc.) is used in a claim as a generic term or within a statement of a claim of any kind, it is understood that additional elements, expressions, etc. may be present without being outside the scope of the corresponding claim or statement. When used in this specification as a transitional term, for example, in the preamble of a claim, it is open-ended in the same way that the terms "comprising" and "including" are open-ended.The term "and / or", when used, for example, in a form such as A, B and / or C, refers to any combination or subset of A, B, C, such as (1) only A, (2) only B, (3) only C, (4) A with B, (5) A with C and (6) B with C, or (7) A with B and C. As used herein in the context of describing structures, components, elements, objects and / or things, the term "at least one of A and B" is intended to refer to implementations that include any of the following: (1) at least one of A, (2) at least one of B, or (3) at least one of A and at least one of B.Likewise, the phrase "at least one of A or B," as used herein in the context of describing structures, components, elements, objects, and / or things, is intended to refer to implementations that include any of the following: (1) at least one of A, (2) at least one of B, or (3) at least one of A and at least one of B. As used herein in the context of describing the performance or execution of processes, instructions, acts, activities, and / or steps, the phrase "at least one of A and B" is intended to refer to implementations that include any of the following: (1) at least one of A, (2) at least one of B, or (3) at least one of A and at least one of B.Similarly, the phrase “at least one of A or B,” as used herein in connection with describing the performance or execution of processes, instructions, acts, activities, and / or steps, shall refer to implementations that include any of the following: (1) at least one of A, (2) at least one of B, or (3) at least one of A and at least one of B.

[0062] As used herein, references to the singular (e.g., "a," "an," "first," "second," etc.) do not exclude a plurality. The term "an" object, as used in this specification, refers to one or more of these objects. The terms "a" (or "an"), "one or more," and "at least one" are used interchangeably in this specification. Moreover, although listed individually, a plurality of means, elements, or acts may be implemented, e.g., by the same entity or object. In addition, while individual features may be included in different examples or claims, they may be combined, and inclusion in different examples or claims does not imply that a combination of features is not possible and / or advantageous.

[0063] Fig. 9 is a flowchart illustrating example machine-readable instructions and / or example operations 900 performed by a programmable circuit for assembling a steering actuator, such as the example steering systems 200, 260, 800, 860 of Fig. 2A, Fig. 2B, Fig. 3, Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8A and Fig. 8B. The exemplary machine-readable instructions and / or exemplary operations 900 of Fig. 9 begin at block 902, where a first bevel gear (e.g., sector gear 220) is adjusted to a position and axial support is provided. For example, the second axial positioning screw 246, the cover 242, and / or the spring 306 can position and support the output shaft 116 and, in turn, the sector gear 220.

[0064] At block 904, a second bevel gear (e.g. the second pinion 214 from the Fig. 2A-2B, the third pinion 822 from the Fig. 8A-8B) is moved axially to engage the first bevel gear. For example, the first axial positioning screw 244 may move the first gear assembly 204 from Fig. 2A-2B and / or the second gear assembly 812 from Fig. 8A-8B to engage the second pinion 214 and / or the third pinion 822 with the sector gear 220. In some examples, another axial control mechanism moves the first bevel gear.

[0065] At block 906, the first and second bevel gears are rotated, and a torque that generated and / or results from the rotation is measured. For example, an input torque to the second bevel gear (e.g., the first gear assembly 204 of the Fig. 2A-2B, the second gear arrangement 812 from Fig. 8A-8B) and an output torque can be measured at the first bevel gear (e.g., the gear segment 220, the output shaft 116).

[0066] At block 908, the output torque is compared to a torque threshold (e.g., 1 Nm). For example, the torque threshold may be set based on the input torque and a gear ratio between the second bevel gear and the first bevel gear. If the output torque meets (e.g., is greater than, greater than, or equal to) the torque threshold (e.g., block 908 returns a result of "YES"), operations 900 jump to block 912. Otherwise, if the output torque does not meet (e.g., is less than, equal to, or less than) the torque threshold (e.g., block 908 returns a result of "NO"), operations 900 continue to block 910.

[0067] At block 910, the first bevel gear and / or the second bevel gear is / are moved axially (e.g., along their respective rotational axes) to adjust the meshing between the bevel gears and thus the output torque resulting from the rotation of the second bevel gear. For example, the first axial positioning screw 244 may be Fig. 2-4 and 6-7 and / or the second axial positioning screw 246 from Fig. 2-5 move the bevel gears. In some examples, another axial control mechanism moves the first bevel gear and / or the second bevel gear. After block 910 is completed, operations 900 return to block 906.

[0068] At block 912, the respective axial positions of the bevel gears are locked. For example, the first axial positioning screw 244 and the second axial positioning screw 246 may be caulked to the housing 104 or the sub-housing. Alternatively, the first axial positioning screw 244 and the second axial positioning screw 246 may be secured with a locknut.

[0069] From the foregoing, it will be appreciated that exemplary systems, devices, articles of manufacture, and methods have been disclosed that enable steering torque to be transmitted to a pitman arm with a single rotary motion. Consequently, the lack of linear motion in the steering systems disclosed herein allows the steering systems to occupy a smaller space, providing versatility in the vehicles in which the steering systems may be used and / or in the area in which the steering system may be positioned. Furthermore, the steering systems disclosed herein generate sufficient power to steer heavier vehicles, such as trucks, while occupying the reduced space and utilizing electric power assistance.

[0070] The above examples of steering systems can be used with vehicles. While each example steering system disclosed above includes certain features, it should be understood that it is not necessary that a particular feature of an example steering system be used exclusively with that example. Rather, any of the features described above and / or illustrated in the drawings can be combined with any of the examples, in addition to or in place of any of the other features of those examples. Features of one example and features of another example are not mutually exclusive. Instead, the scope of this disclosure encompasses any combination of any of the features.

[0071] This document discloses exemplary rotary steering systems. Further examples and combinations thereof include the following: Example 1 includes a vehicle steering system comprising an input gear attached to one end of an input shaft, a first idler gear attached to a first pinion gear and meshing with the input gear, a second idler gear attached to a second pinion gear and meshing with one of the first idler gear and a third idler gear, a motor attached to a third pinion gear, a motor attached to a third pinion gear, the third pinion gear meshing with the second idler gear, the motor rotating the first idler gear and the first pinion gear, a third gear attached to a shaft, the third gear meshing with the first pinion gear, the third gear and the shaft rotating as the first idler gear rotates, and a steering arm coupled to the shaft, the steering arm coupled to a steering push rod for rotating the wheels of a vehicle as the shaft rotates. Example 2 includes the vehicle steering system of Example 1, wherein the first idler gear and the first pinion gear are aligned along a first rotational axis, wherein the third gear and the shaft are aligned along a second rotational axis, and wherein the first rotational axis intersects the second rotational axis. Example 3 includes the vehicle steering system of Example 2, wherein the input wheel is aligned along a third rotational axis that is substantially parallel to the first rotational axis. Example 4 includes the vehicle steering system of Example 1, wherein the first pinion and the third gear are bevel gears. Example 5 includes the vehicle steering system of Example 1, wherein the third gear is a gear segment. Example 6 includes the vehicle steering system of Example 1, wherein the shaft includes a first end and a second end facing in opposite directions, the third gear positioned at the first end of the shaft and facing at least partially in a same direction as the end of the shaft. Example 7 includes the vehicle steering system of Example 6, wherein the steering arm is coupled to the shaft at the second end of the shaft. Example 8 includes the vehicle steering system of Example 1, wherein the shaft includes an opening aligned along a rotational axis of the shaft, further including a positioning screw positioned in the opening and a retaining ring to couple the positioning screw to the shaft, the shaft being axially movable with the positioning screw. Example 9 includes the vehicle steering system of Example 8, further including a washer positioned around the shaft and in contact with the retaining ring. Example 10 includes the vehicle steering system of Example 1, wherein the first idler gear includes an opening aligned along a rotational axis of the first idler gear, further including a positioning screw positioned in the opening and a retaining ring to couple the positioning screw to the first idler gear, the first idler gear being axially movable with the positioning screw. Example 11 includes the vehicle steering system of Example 1, further including a housing positioned around the shaft between the third gear and the steering arm, and at least one roller bearing coupled to the housing and the shaft. Example 12 includes the vehicle steering system of Example 11, wherein the housing includes a protruding edge protruding away from a body of the shaft about which the housing is positioned, and wherein the third gear is positioned over the protruding edge. Example 13 includes a vehicle steering system comprising an input shaft having an input gear, a first gear assembly having a first idler gear attached to a first pinion gear, the first idler gear meshing with the input gear, a second gear assembly having a second idler gear attached to a second pinion gear, the second pinion gear meshing with one of the first idler gear and a third idler gear, and an output shaft having a third gear meshing with the first pinion gear, a motor attached to a third pinion gear, the third pinion gear meshing with the second idler gear, the motor generating torque that rotates the input shaft, the first gear assembly, the second gear assembly, and the output shaft, and a steering arm coupled to the output shaft, the steering arm coupled to a steering pushrod to rotate the wheels of a vehicle.when the output shaft rotates., Example 14 includes the vehicle steering system of Example 13, wherein the first gear assembly is aligned along a first rotational axis, wherein the output shaft is aligned along a second rotational axis, and wherein the first rotational axis and the second rotational axis intersect. Example 15 includes the vehicle steering system of Example 13, wherein the first gear assembly includes an opening aligned along a rotational axis of the first gear assembly, and further includes an axial position adjustment screw positioned in the opening and a retaining ring to connect the axial position adjustment screw to the first gear assembly. Example 16 includes the vehicle steering system of Example 13, further including a housing positioned about the output shaft between the third gear and the steering arm, a first roller bearing coupled to the housing and the output shaft at a first end of the housing, and a second roller bearing coupled to the housing and the output shaft at a second end of the housing opposite the first end. Example 17 includes a device comprising an input shaft having an input gear, a first gear set having a first idler gear and a first pinion gear, the first idler gear meshing with the input gear, a second gear set having a second idler gear attached to a second pinion gear, the second pinion gear meshing with the first idler gear, an output shaft having a sector gear and splines, the sector gear disposed at a first end of the output shaft, the splines disposed at a second end of the output shaft opposite the first end, and the sector gear meshing with the first pinion gear, and a motor attached to a third pinion gear, the third pinion gear meshing with the second idler gear, the motor providing torque that rotates the input shaft, the first gear set, the second gear set, and the output shaft. Example 18 includes the apparatus of Example 17, further including a steering arm coupled to the output shaft at the splines, the steering arm to be coupled to a steering push rod to pivot wheels of a vehicle when the output shaft rotates. Example 19 includes the device of Example 17, wherein the first gear set is aligned along a first rotational axis, wherein the output shaft is aligned along a second rotational axis, and wherein the first rotational axis and the second rotational axis intersect. Example 20 includes the device of Example 17, wherein the first gear set has an opening aligned along a rotational axis of the first gear set, and further includes an axial adjustment screw positioned in the opening and coupled to the first gear set.

[0072] The following claims are hereby incorporated by reference into this Detailed Description. While certain exemplary systems, devices, articles of manufacture, and methods have been disclosed herein, the scope of this specification is not limited thereto. On the contrary, this specification covers all systems, devices, articles of manufacture, and methods that properly fall within the scope of the claims of this specification.

Claims

[1] Vehicle steering system, comprising: an input gear attached to one end of an input shaft; a first intermediate gear fixed to a first pinion gear, the first intermediate gear meshing with the input gear; a second intermediate gear fixed to a second pinion, the second pinion meshing with the first intermediate gear or a third intermediate gear; a motor attached to a third pinion gear, the third pinion gear meshing with the second idler gear, the motor rotating the first idler gear and the first pinion gear; a fourth gear fixed to a shaft, the fourth gear meshing with the first pinion gear such that the fourth gear and the shaft rotate when the first idler gear rotates; and a steering arm coupled to the shaft, the steering arm coupled to a steering push rod for turning the wheels of a vehicle as the shaft rotates. [2] The vehicle steering system of claim 1, wherein the first idler gear and the first pinion are aligned along a first axis of rotation, wherein the fourth gear and the shaft are aligned along a second axis of rotation, and wherein the first axis of rotation intersects the second axis of rotation. [3] A vehicle steering system according to claim 2, wherein the input gear is aligned along a third axis of rotation that is substantially parallel to the first axis of rotation. [4] A vehicle steering system according to claim 2 or claim 3, wherein the third pinion is aligned along a fourth axis of rotation substantially parallel to the first axis of rotation. [5] A vehicle steering system according to any one of claims 2-4, wherein the second axis of rotation is substantially perpendicular to the first axis of rotation. [6] A vehicle steering system according to any one of the preceding claims, wherein the first pinion and the fourth gear are bevel gears. [7] A vehicle steering system according to any one of the preceding claims, wherein the fourth gear is a toothed segment. [8] A vehicle steering system according to any preceding claim, wherein the shaft includes a first end and a second end facing in opposite directions, the fourth gear being positioned at the first end of the shaft and facing at least partially in a same direction as the end of the shaft. [9] The vehicle steering system of claim 8, wherein the steering arm is coupled to the shaft at the second end of the shaft. [10] A vehicle steering system according to any one of the preceding claims, wherein the shaft includes an opening aligned along an axis of rotation of the shaft, further comprising: a positioning screw positioned in the opening; and a retaining ring for coupling the positioning screw to the shaft, whereby the shaft is axially movable with the positioning screw. [11] The vehicle steering system of claim 10, further including a washer positioned around the shaft and in contact with the retaining ring. [12] A vehicle steering system according to any one of the preceding claims, wherein the first idler gear has an opening aligned along a rotational axis of the first idler gear, further comprising: a positioning screw positioned in the opening; and a retaining ring for coupling the positioning screw to the first intermediate gear, wherein the first intermediate gear is axially movable with the positioning screw. [13] Vehicle steering system according to one of the preceding claims, further comprising: a housing positioned around the shaft between the fourth gear and the steering arm; and at least one roller bearing coupled to the housing and the shaft. [14] A vehicle steering system according to claim 13, wherein the housing includes a projecting edge projecting away from a body of the shaft around which the housing is positioned, and wherein the fourth gear is positioned over the projecting edge. [15] A vehicle steering system according to any preceding claim, further comprising a third idler gear fixed to a fourth pinion gear, the second pinion gear meshing with the third idler gear and the fourth pinion gear meshing with the first idler gear.

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