Worm gear reducer

Abstract

This invention provides a worm gear reducer that easily achieves a high level of both suppression of abnormal noise when torque is input in reverse and ensuring torque transmission efficiency during normal operation. [Solution] The inner diameter side member 5 is equipped with a biasing leaf spring 6 that biases it toward the worm wheel. The biasing leaf spring 6 is positioned on the side furthest from the worm wheel with respect to the biasing direction by the biasing leaf spring 6, in the portion between the outer circumferential surface of the inner diameter side member and the inner circumferential surface of the outer diameter side member 9. It has a load point, which is the contact portion with the outer circumferential surface of the inner diameter side member 5, and a fulcrum, which is the portion of the contact portion with the inner circumferential surface of the outer diameter side member 9 that is closest to the load point. It exhibits a nonlinear spring characteristic such that the spring constant increases as the position of the fulcrum moves closer to the load point as the amount of deflection in the first direction increases.

Description

Technical Field

[0001] The present disclosure relates to a worm reducer that can be incorporated into an electric power steering device or the like.

[0002] In the field of steering devices, an electric power steering device that uses an electric motor as an auxiliary power source to reduce the force required for a driver to operate a steering wheel has become widespread.

[0003] The electric power steering device includes a worm reducer for increasing the torque of the electric motor. The worm reducer includes a housing, a worm wheel, and a worm. The housing has a wheel housing portion and a worm housing portion having a central axis that is twisted with respect to the central axis of the wheel housing portion and has an axial intermediate portion opening into the wheel housing portion. The worm wheel has wheel teeth on its outer peripheral surface and is rotatably supported inside the wheel housing portion. The worm has worm teeth that mesh with the wheel teeth on its outer peripheral surface and is rotatably supported inside the worm housing portion.

[0004] The torque of the electric motor is increased by being transmitted to the worm wheel via the worm, and then is applied as auxiliary power to a steering force transmission member such as a steering shaft, a pinion shaft, or a rack shaft of a steering gear unit. Thereby, the force required for the driver to operate the steering wheel is reduced.

[0005] In the worm reducer, there is an inevitable backlash at the meshing portion between the wheel teeth and the worm teeth based on dimensional errors and assembly errors of the respective components constituting the worm reducer. Based on the presence of this backlash, a noisy tooth engagement sound may occur at the meshing portion when changing the rotation direction of the steering wheel.

[0006] Japanese Patent Publication No. 2020-128803 describes a structure for biasing the tip of a worm toward the worm wheel in order to suppress the generation of a tooth-striking noise at the meshing portion between the wheel teeth and the worm teeth. This structure comprises an external fitting member fitted onto a support bearing that rotatably supports the tip of the worm and arranged to allow for near and far movement relative to the worm wheel, and a biasing spring installed between the external fitting member and the worm housing.

[0007] The biasing spring is elastically deformed, and its elastic restoring force biases the outer fitting member toward the worm wheel. This suppresses backlash at the meshing portion between the wheel teeth and the worm teeth, thereby reducing the generation of teeth-clamping noise. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Patent Publication No. 2020-128803 [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] The conventional structure described in Japanese Patent Publication No. 2020-128803 has room for improvement in the following respects.

[0010] In worm gear reducers incorporated into steering systems, large torque can be reversed from the tire to the worm wheel when the car's tires drive over a curb or when the car travels on rough roads. When such reverse torque input occurs, a large meshing reaction force acts on the worm from the meshing point between the worm teeth and the wheel teeth, causing the worm to displace away from the worm wheel, which increases the elastic deformation of the biasing spring. As a result, the biasing spring, or any component surrounding the biasing spring, may collide forcefully with an adjacent component, potentially producing an unpleasant knocking sound.

[0011] Furthermore, the torque applied in reverse from the tire to the worm wheel can result in torque oscillations where the direction of rotation repeatedly reverses. In such cases, there is a possibility of repeated knocking noises due to collisions between components, or rattling noises from the worm teeth and wheel teeth.

[0012] To suppress the generation of these abnormal noises, it is necessary to ensure that the force of collisions between components is sufficiently suppressed by the elasticity of the biasing spring; specifically, it is required to increase the spring constant of the biasing spring.

[0013] On the other hand, during normal operation when no reverse torque input occurs, it is desirable to ensure sufficient torque transmission efficiency from the worm to the worm wheel by keeping the frictional force acting on the meshing portion between the worm teeth and the wheel teeth small, regardless of the displacement of the worm due to the generation of meshing reaction force. To achieve this, it is necessary to keep the biasing force by the biasing spring small during normal operation, specifically by reducing the spring constant of the biasing spring.

[0014] However, in the conventional structure described in Japanese Patent Publication No. 2020-128803, the spring constant of the biasing spring is constant, making it difficult to satisfy the two mutually exclusive requirements mentioned above.

[0015] The purpose of this disclosure is to provide a worm gear reducer that can easily achieve a high level of both suppression of abnormal noise generation when torque is input in reverse and ensuring torque transmission efficiency during normal operation. [Means for solving the problem]

[0016] A worm gear reducer according to one aspect of the present disclosure comprises a housing, a worm wheel, a worm, a support bearing, and a biasing leaf spring.

[0017] The housing comprises a wheel housing and a worm housing having a central axis that is twisted relative to the central axis of the wheel housing, and whose axial intermediate portion opens into the wheel housing.

[0018] The worm wheel has wheel teeth on its outer circumference and is rotatably supported inside the wheel housing.

[0019] The worm has worm teeth on its outer circumferential surface that mesh with the wheel teeth, and is rotatably supported inside the worm housing.

[0020] The support bearing is fitted onto the tip of the worm.

[0021] The biasing leaf spring biases the inner diameter side member, which is the support bearing or an external fitting member fitted onto the support bearing, toward the worm wheel.

[0022] In a worm gear reducer according to one aspect of the present disclosure, the biasing leaf spring is positioned on the side furthest from the worm wheel with respect to a first direction, which is the biasing direction by the biasing leaf spring, in the portion between the outer circumferential surface of the inner diameter side member and the inner circumferential surface of the outer diameter side member, which is the worm housing or an internal fitting member fitted into the worm housing.

[0023] The biasing leaf spring has a load point which is the contact portion with the outer circumferential surface of the inner diameter side member, and a fulcrum which is the portion of the contact portion with the inner circumferential surface of the outer diameter side member that is located closest to the load point.

[0024] The biasing leaf spring exhibits a nonlinear spring characteristic such that the spring constant increases as the amount of deflection in the first direction increases, causing the position of the support point to move closer to the load point. The manner in which the spring constant increases with increasing deflection in the first direction may be a stepwise increase or a continuous increase.

[0025] In the worm reducer according to one aspect of the present disclosure, the biasing plate spring is arranged to extend in a third direction that is orthogonal to both the first direction and a second direction that is the axial direction of the worm housing portion, and one end of the biasing plate spring in either one of the third directions is cantilever-supported with respect to the outer diameter side member, and the load point is provided at the other end in the third direction.

[0026] In the worm reducer according to one aspect of the present disclosure, one end of the biasing plate spring is cantilever-supported with respect to the outer diameter side member by using a pin arranged to extend in the second direction.

[0027] In the worm reducer according to one aspect of the present disclosure, the outer diameter side member is made of an aluminum alloy, and the pin is made of a ferroalloy.

[0028] In the worm reducer according to one aspect of the present disclosure, the inner peripheral surface of the outer diameter side member has a main holding portion and a sub-holding portion. The main holding portion is slightly larger than the outer peripheral surface of the inner diameter side member, and the inner diameter side member is arranged inside. The sub-holding portion projects outward from an end portion of the main holding portion that is far from the worm wheel in the first direction, and the biasing plate spring is arranged inside.

[0029] The main holding portion exists in a circumferential range that can intersect a radial straight line L1 including a vector of the meshing reaction force F1 applied to the worm from the meshing portion of the worm teeth and the wheel teeth when the worm rotates in a predetermined direction when viewed from the second direction, and can intersect a radial straight line L2 including a vector of the meshing reaction force F2 applied to the worm from the meshing portion when the worm rotates in a direction opposite to the predetermined direction.

[0030] The inclination angle of the radial straight line L2 with respect to the third direction is smaller than the inclination angle of the radial straight line L1 with respect to the third direction. In this case, a portion of the sub-holding portion where one end of the biasing plate spring is arranged can be arranged on the same side as the radial straight line L2 with respect to the central axis of the worm in the third direction.

[0031] In a worm gear reducer according to one aspect of the present disclosure, the outer diameter side member includes a plurality of corners arranged spaced apart in the third direction, which come into contact with the biasing leaf spring during operation.

[0032] In a worm gear reducer according to one aspect of the present disclosure, the biasing leaf spring is configured to be able to contact two or more of the plurality of corners simultaneously during operation.

[0033] In a worm gear reducer according to one aspect of the present disclosure, the outer diameter side member is provided with a convex curved surface portion that contacts the biasing leaf spring during operation.

[0034] A worm gear reducer according to one aspect of the present disclosure includes elastic clamping means for clamping the inner diameter side member from both sides with respect to the third direction. The elastic clamping means has a pair of clamping leaf springs arranged on both sides in the third direction of the portion between the outer circumferential surface of the inner diameter side member and the inner circumferential surface of the outer diameter side member.

[0035] Each of the clamping leaf springs constituting the pair exhibits a nonlinear spring characteristic such that its spring constant increases as the amount of deflection in the third direction increases. The manner in which the spring constant increases as the amount of deflection in the third direction increases may be a stepwise increase or a continuous increase.

[0036] This disclosure can be implemented by combining the respective embodiments described above as appropriate, to the extent that they do not create any contradictions. [Effects of the Invention]

[0037] According to one embodiment of the worm gear reducer of this disclosure, it is easy to achieve a high level of both suppression of abnormal noise generation when torque is input in reverse and ensuring torque transmission efficiency during normal operation. [Brief explanation of the drawing]

[0038] [Figure 1]Figure 1 shows an electric power steering device incorporating a worm gear reducer, which is a first example of an embodiment of the present disclosure. [Figure 2] Figure 2 is a cross-sectional view of AA in Figure 1. [Figure 3] Figure 3 is an enlarged view of the upper right portion of Figure 2. [Figure 4] Figure 4 is an exploded perspective view of the part shown in Figure 3. [Figure 5] Figure 5 shows the part shown in Figure 3 with the cover and retaining ring removed, viewed from the right side of Figure 3. [Figure 6] Figure 6 is an enlarged view of section B in Figure 5. [Figure 7] Figure 7 is an enlarged view of section C in Figure 5. [Figure 8] Figure 8 shows the housing in the first example, viewed from the right side of Figure 3. [Figure 9] Figure 9 is a perspective view showing the support bearing, biasing leaf spring, and elastic clamping means separately in the first example. [Figure 10] Figure 10 is a diagram showing the components shown in Figure 9 separated. [Figure 11] Figure 11(a) is a side view of the biasing leaf spring in the first example, Figure 11(b) is a view of Figure 11(a) from above, Figure 11(c) is a view of Figure 11(a) from below, Figure 11(d) is a view of Figure 11(a) from the left, and Figure 11(e) is a view of Figure 11(a) from the right. [Figure 12] Figure 12(a) is a side view of the elastic clamping means in the first example, Figure 12(b) is a view of Figure 12(a) from above, Figure 12(c) is a view of Figure 12(a) from below, Figure 12(d) is a view of Figure 12(a) from the left, and Figure 12(e) is a view of Figure 12(a) from the right. [Figure 13] Figures 13(a) to 13(d) schematically show how the amount of deflection of the biasing leaf spring in the first direction increases in the first example. [Figure 14] Figure 14 is a diagram (conceptual diagram) showing the spring characteristics of the biasing leaf spring in the first example. [Figure 15] Figures 15(a) to 15(c) schematically show how the amount of deflection in the third direction of the elastic clamping means (clamping leaf spring) increases in the first example. [Figure 16] Figure 16 is a diagram (conceptual diagram) showing the spring characteristics of the elastic clamping means (clamping leaf spring) in the first example. [Figure 17] Figures 17(a) to 17(c) schematically show how the amount of deflection of the elastic clamping means (clamping leaf spring) in the third direction does not change with movement in the first direction in the first example. [Figure 18] Figure 18 is a diagram corresponding to Figure 13(a) relating to a second example of an embodiment of the present disclosure. [Modes for carrying out the invention]

[0039] [Example 1] A first example of the embodiment of this disclosure will be described with reference to Figures 1 to 17.

[0040] (1) Worm gear reducer The worm gear reducer described herein is applicable to worm gear reducers incorporated into various mechanical devices, but this example describes the application of the disclosure to a worm gear reducer incorporated into an electric power steering system for automobiles.

[0041] As shown in Figures 1 to 5, the worm gear reducer 1 in this example comprises a housing 2, a worm wheel 3, a worm 4, a support bearing 5, and a biasing leaf spring 6.

[0042] The housing 2 comprises a wheel housing 8 and a worm housing 9 having a central axis that is twisted relative to the central axis of the wheel housing 8, and whose axial intermediate portion opens into the wheel housing 8. In this example, the housing 2 is made of an aluminum alloy. However, when implementing this disclosure, the material of the housing is arbitrary as long as the required rigidity of the housing can be ensured.

[0043] The wheel housing 8 is cylindrical in shape. In Figure 2, the central axis of the wheel housing 8 extends in the front-to-back direction.

[0044] The worm housing 9 is cylindrical in shape and has openings at both ends in the axial direction. In Figure 2, the central axis of the worm housing 9 extends in the left-right direction. One axial opening of the worm housing 9 is closed by a cover 10 fitted to the opening using a retaining ring 47. The other axial opening of the worm housing 9 is closed by an electric motor 11 that is coupled and fixed to the housing 2.

[0045] With respect to the worm housing 9 and each component including the worm 4 housed in the worm housing 9, one axial side is the right side in Figure 2, and the other axial side is the left side in Figure 2.

[0046] The worm wheel 3 has wheel teeth 12 on its outer circumference. In this example, the wheel teeth are made up of helical gears. The worm wheel 3 is rotatably supported inside the wheel housing 8. In this example, the worm wheel 3 is externally fitted and fixed to a portion of the axial direction of a rotating shaft (in this example, the front part of the steering shaft 50 in the longitudinal direction of the vehicle) that is rotatably supported inside the wheel housing 8.

[0047] The worm 4 has worm teeth 13 on its outer circumferential surface in the axial middle portion that mesh with the wheel teeth 12 of the worm wheel 3, and is rotatably supported inside the worm housing 9. In this example, the worm teeth 13 are threaded, and their twisting direction is a right-hand thread. However, the twisting direction can also be a left-hand thread.

[0048] The base portion of the worm 4 (the portion closer to the other axial end) is rotatably supported by a ball bearing 14 in the worm housing 9. In this example, the outer ring of the ball bearing 14 is fitted into the worm housing 9 with a radial gap in between, and the inner ring of the ball bearing 14 is fitted onto the base portion of the worm 4 with a radial gap in between. This allows the base portion of the worm 4 to be supported in the worm housing 9 in a manner that enables rotation and oscillating displacement. The outer ring of the ball bearing 14 can also be fitted into the worm housing 9 by interference fit.

[0049] Furthermore, the structure that supports the base portion of the worm 4 relative to the worm housing 9, enabling rotational and oscillating displacement, is not limited to the structure in this example; various structures can be adopted.

[0050] The base end (other axial end) of the worm 4 is connected to the tip end (one axial end) of the output shaft 15 of the electric motor 11 using a coupling 16, enabling torque transmission and oscillating displacement. The base end of the worm 4 can also be connected to the tip end of the output shaft 15 of the electric motor 11 using a spline engagement or the like, enabling torque transmission and oscillating displacement.

[0051] The support bearing 5 is fitted onto the tip (one axial end) of the worm 4.

[0052] In this example, the support bearing 5 is made of ball bearings. Specifically, as shown in Figure 3, the support bearing 5 comprises an inner ring 17, an outer ring 18, and a plurality of balls 19 arranged between an inner ring raceway provided on the outer circumference of the inner ring 17 and an outer ring raceway provided on the inner circumference of the outer ring 18. The inner ring 17 is externally fitted and fixed to the tip of the worm 4. In this disclosure, the support bearing may also be made of other types of bearings, such as roller bearings.

[0053] In this example, the inner circumferential surface of the worm housing 9 has a small-diameter cylindrical surface portion 20 near the end on one axial side, which is smaller in diameter than the outer circumferential surface of the support bearing 5, i.e., the outer circumferential surface of the outer ring 18, and a retaining portion 21 adjacent to the small-diameter cylindrical surface portion 20 on one axial side, which is larger in diameter than the small-diameter cylindrical surface portion 20. The small-diameter cylindrical surface portion 20 and the retaining portion 21 are connected by a stepped surface 22 facing one axial side. In this example, the support bearing 5 is positioned inside the retaining portion 21, allowing for radial movement.

[0054] In the following description, the biasing direction by the biasing leaf spring 6, which is the direction in which the worm 4 moves toward or away from the worm wheel 3 (the up and down direction in Figures 2, 3, and 5), will be referred to as the "first direction," the axial direction of the worm 4 and the worm housing 9 (the left and right direction in Figures 2 and 3, and the front and back direction in Figure 5) will be referred to as the "second direction," and the direction perpendicular to both the first and second directions (the front and back direction in Figures 2 and 3, and the left and right direction in Figure 5) will be referred to as the "third direction." The tip of the worm 4 corresponds to one end of the worm 4 in the axial direction and in the second direction.

[0055] As shown in Figures 5 and 8, the retaining portion 21 of the worm housing 9 comprises a main retaining portion 23, a sub-retaining portion 24, and a locking portion 25. The main retaining portion 23 is arranged substantially coaxially with the small-diameter cylindrical surface portion 20 and has a substantially cylindrical shape that is slightly larger than the outer circumferential surface of the support bearing 5. The sub-retaining portion 24 protrudes outward from the end of the main retaining portion 23 on the side furthest from the worm wheel 3 in the first direction (the upper side in Figures 5 and 8). The locking portion 25 protrudes outward from the end of the main retaining portion 23 on the side closer to the worm wheel 3 in the first direction.

[0056] The main holding portion 23 is the part in which the support bearing 5 is arranged to allow radial movement. The worm gear reducer 1 in this example further includes an elastic clamping means 7 arranged between the outer circumferential surface of the support bearing 5 and the inner circumferential surface of the main holding portion 23.

[0057] Of the main holding portion 23, both ends in the third direction are composed of a pair of flat portions 26 (see Figure 7) that extend in the first direction. The pair of flat portions 26 are the parts that come into contact with the pair of clamping leaf springs 41 that constitute the elastic clamping means 7. The distance between the pair of flat portions 26 in the third direction is greater than the diameter of the outer circumferential surface of the support bearing 5. The length of the pair of flat portions 26 in the first direction is ensured to be greater than the stroke amount that allows the elastic clamping means 7 to move in the first direction together with the tip of the worm 4 and the support bearing 5 during operation.

[0058] This ensures that, regardless of the movement of the elastic clamping means 7 in the first direction, the pair of clamping leaf springs 41 constituting the elastic clamping means 7 remain in contact with the pair of flat surfaces 26.

[0059] Of the main holding portion 23, the portion that deviates circumferentially from the pair of flat portions 26 is composed of a cylindrical surface portion 27 with a larger diameter than the outer circumferential surface of the support bearing 5. In this disclosure, the pair of flat portions of the main holding portion can be omitted, and the main holding portion can be composed solely of the cylindrical surface portion.

[0060] In the worm gear reducer 1 of this example, when torque is transmitted from the worm 4 to the worm wheel 3, a meshing reaction force is applied to the worm 4 from the meshing portion between the wheel teeth 12 and the worm teeth 13. This meshing reaction force includes not only a first-direction component but also a third-direction component. The direction of the third-direction component of this meshing reaction force is opposite to that of the case when the worm 4 rotates in a predetermined direction and when the worm 4 rotates in the opposite direction. Furthermore, the ratio of the first-direction component to the third-direction component included in this meshing reaction force is different from that of the case when the worm 4 rotates in a predetermined direction and when it rotates in the opposite direction.

[0061] In other words, when torque is transmitted between the worm 4 and the worm wheel 3, a meshing reaction force F1 or F2 is applied to the tip of the worm 4, depending on the rotation direction of the worm 4, as shown in Figure 5. The meshing reaction forces F1 and F2 are oriented in directions asymmetrical with respect to the third direction. In this example, the twisting direction of the worm teeth 13 is a right-hand thread, but if the twisting direction of the worm teeth 13 is a left-hand thread, the directions of the meshing reaction forces F1 and F2 in Figure 5 will be reversed with respect to the third direction. In this case, the structure of the part shown in Figure 5 of this example can also be reversed with respect to the third direction, that is, reversed left and right in Figure 5.

[0062] As shown in Figure 5, the circumferential range where the cylindrical surface portion 27 of the main holding portion 23 exists includes the same circumferential position as the vectors of the meshing reaction forces F1 and F2 when viewed from the second direction. That is, the radial lines L1 and L2 containing the vectors of the meshing reaction forces F1 and F2 intersect with a portion of the circumferential direction of the cylindrical surface portion 27 of the main holding portion 23.

[0063] The sub-retaining portion 24 is the part in which the biasing leaf spring 6 is positioned. The sub-retaining portion 24 has a large recess 28 on one side in the third direction (right side in Figures 5 and 8) that is recessed toward the same side in the third direction. The sub-retaining portion 24 has a small recess 29 on the other side in the third direction (left side in Figures 5 and 8) that is recessed toward the side furthest from the worm wheel 3 with respect to the first direction.

[0064] The sub-holding portion 24 has a first inclined surface portion 30 and a second inclined surface portion 31 between the large recess 28 and the small recess 29, starting from the side of the large recess 28. Each of the first inclined surface portion 30 and the second inclined surface portion 31 is composed of a plane that is inclined in a direction that moves toward the other side with respect to the third direction and toward the side away from the worm wheel 3 with respect to the first direction.

[0065] As shown in Figure 6, the inclination angle θ2 of the second inclined surface 31 with respect to the third direction is greater than the inclination angle θ1 of the first inclined surface 30 with respect to the third direction (θ2 > θ1). In this example, when viewed from the second direction, the length of the second inclined surface 31 is longer than the length of the first inclined surface 30. The large recess 28 and the first inclined surface 30 are connected by the first corner 32. The first inclined surface 30 and the second inclined surface 31 are connected by the second corner 33. The second inclined surface 31 and the small recess 29 are connected by the third corner 34.

[0066] In other words, the first corner 32, the second corner 33, and the third corner 34 are positioned in the order of the first corner 32, the second corner 33, and the third corner 34 in the direction away from the pin 36 located in the large recess 28 with respect to the third direction (to the left in Figures 5, 6, and 8), and in the direction away from the worm wheel 3 with respect to the first direction (up in Figures 5, 6, and 8). The first corner 32, the second corner 33, and the third corner 34, which are spaced apart in the third direction, are the parts that come into contact with the biasing leaf spring 6 during operation.

[0067] As shown in Figures 5 and 8, the locking portion 25 is a part for engaging a portion of the elastic clamping means 7 in the circumferential direction. In the illustrated example, the locking portion 25 is composed of a semi-cylindrical concave surface.

[0068] In this example, the worm housing 9 has a recess 35 that opens to the portion of the stepped surface 22 located inside the large recess 28. The other axial end of a cylindrical pin 36, which is arranged to extend in a second direction, is press-fitted into the recess 35. The pin 36 is a component used to cantilever support the biasing leaf spring 6 to the worm housing. In this example, the pin 36 is made of an iron alloy. However, when implementing this disclosure, the material of the pin 36 is arbitrary as long as the required rigidity of the pin 36 is ensured.

[0069] The biasing leaf spring 6 biases the support bearing 5, which corresponds to the inner diameter side member, toward the worm wheel 3. This suppresses the backlash between the wheel teeth 12 and the worm teeth 13, thereby suppressing the generation of tooth noise. In this disclosure, an external fitting member fitted to the support bearing 5 can also be used as the inner diameter side member. That is, the biasing leaf spring can also be used to bias the external fitting member toward the worm wheel.

[0070] The biasing leaf spring 6 is entirely located inside the worm housing 9. In this example, as shown in Figure 5, the biasing leaf spring 6 is located on the side furthest from the worm wheel 3 in the first direction, in the portion between the outer circumferential surface of the support bearing 5 and the retaining portion 21 provided on the inner circumferential surface of the worm housing 9, which corresponds to the outer diameter side member. More specifically, the biasing leaf spring 6 is located inside the sub-retaining portion 24 that constitutes the retaining portion 21.

[0071] Furthermore, when implementing this disclosure, an internal fitting member fitted into the worm housing portion may be used as the outer diameter side member. That is, the inner circumferential surface of the internal fitting member may be provided with a retaining portion 21.

[0072] In this example, the biasing leaf spring 6 has a load point P, which is the contact point with the outer circumferential surface of the support bearing 5, and a fulcrum S, which is the part of the contact point with the holding portion 21 that is closest to the load point P (see Figure 13(a)). Furthermore, the biasing leaf spring 6 exhibits nonlinear spring characteristics such that the spring constant increases as the amount of deflection in the first direction increases, causing the position of the fulcrum S to move closer to the load point P.

[0073] In this example, the biasing leaf spring 6, as shown in Figures 11(a) to 11(e), comprises a rectangular flat strip portion 38 with a large aspect ratio, a base portion 39 bent at an obtuse angle from the longitudinal base end (right side in Figure 11(a)) of the strip portion 38 to one side in the thickness direction (lower side in Figure 11(a)), and a folded plate portion 40 that is folded back 180 degrees from the longitudinal tip end (left side in Figure 11(a)) of the strip portion 38 to one side in the thickness direction, with the tip portion overlapping the tip portion of the strip portion 38.

[0074] In this example, the biasing leaf spring 6 is made of a metal plate such as an iron alloy. However, when implementing this disclosure, the material of the biasing leaf spring 6 is arbitrary as long as the required spring stiffness and other properties are ensured.

[0075] As shown in Figure 5, the biasing leaf spring 6 is positioned to extend in the third direction, with one end in the third direction (in this example, one end in the third direction) cantilevered to the worm housing 9, and the other end in the third direction (in this example, the other end in the third direction) has a load point P (see Figure 13(a)).

[0076] In this example, one end of the biasing leaf spring 6 in the third direction is cantilevered to the worm housing 9 using a pin 36 that is positioned to extend in the second direction.

[0077] More specifically, the biasing leaf spring 6 is positioned relative to the surrounding part in the following manner when the worm reducer 1 is unloaded, that is, when the torque transmitted from the worm 4 to the worm wheel 3 is zero and the meshing reaction forces F1 and F2 applied to the tip of the worm 4 are zero.

[0078] The base end of the substrate portion 39 is elastically in contact with the bottom of the large recess 28 that constitutes the sub-holding portion 24. The concave side (lower side in Figure 5), which is one side in the thickness direction of the connection portion between the strip portion 38 and the substrate portion 39, is elastically in contact with the outer circumferential surface of the pin 36. The other side in the thickness direction of the middle portion of the strip portion 38 (upper side in Figure 5) is elastically in contact with the first corner portion 32 that constitutes the sub-holding portion 24. One side in the thickness direction of the tip of the folded plate portion 40 (lower side in Figure 5) is elastically in contact with the end of the outer circumferential surface of the support bearing 5 that is furthest from the worm wheel 3 in the first direction.

[0079] In this example, a folded plate portion 40 is provided on the part of the biasing leaf spring 6 that contacts the outer circumferential surface of the support bearing 5. Therefore, the size of the radial gap between the part of the outer circumferential surface of the support bearing 5 that contacts the biasing spring 6 and the holding portion 21 can be adjusted to an appropriate size based on the presence of the folded plate portion 40.

[0080] The strip portion 38 is not in contact with the second corner portion 33 and the third corner portion 34, and a gap exists between the strip portion 38 and the second corner portion 33 and the third corner portion 34.

[0081] In this state, the biasing leaf spring 6 elastically biases the support bearing 5 toward the worm wheel 3 such that the contact point with the first corner portion 32 becomes the fulcrum S and the contact point with the outer circumferential surface of the support bearing 5 becomes the load point P (see Figure 13(a)).

[0082] In this example, the biasing leaf spring 6 is held in place at the point of use by the frictional force acting on the contact area between the worm housing 9 and the pin 36. Furthermore, the load point P is positioned approximately at the same location as the third corner 34 of the sub-holding portion 24 with respect to the third direction.

[0083] In this example, as the meshing reaction force F1 or F2 applied to the tip of the worm 4 increases, the pressing force applied from the support bearing 5 to the load point P of the biasing leaf spring 6 increases, and the amount of deflection of the biasing leaf spring 6 (strip portion 38) in the first direction increases. Figures 13(a) to 13(d) schematically show how this amount of deflection increases.

[0084] In this example, as the deflection of the biasing leaf spring 6 in the first direction increases, the elastic contact position of the biasing leaf spring 6 with respect to the sub-holding part 24 changes as shown in Figures 13(a) to 13(d). That is, the position of the pivot point S of the biasing leaf spring 6 changes stepwise in the direction of approaching the load point P. As a result, the spring constant of the biasing leaf spring 6 increases stepwise as shown in Figure 14 (conceptual diagram).

[0085] More specifically, as the amount of deflection of the biasing leaf spring 6 in the first direction increases, the elastic contact position of the biasing leaf spring 6 with respect to the sub-holding portion 24 changes from the first corner 32 (1 location) shown in Figure 13(a) to the first corner 32 and the second corner 33 (2 locations) shown in Figure 13(b), then to the second corner 33 (1 location) shown in Figure 13(c), and then to the second corner 33 and the third corner 34 (2 locations) shown in Figure 13(d). In other words, in this example, the biasing leaf spring 6 is configured to be able to contact two or more of its multiple corners simultaneously during operation.

[0086] As shown in Figure 13(a), when the biasing leaf spring 6 is elastically in contact with only the first corner 32 (one location), the pivot point S of the biasing leaf spring 6 is the contact point with the first corner 32. In this state (first stage), the spring constant of the biasing leaf spring 6 is relatively small, as shown in Figure 14. In this example, during normal operation when no reverse torque input occurs, the amount of deflection of the biasing leaf spring 6 in the first direction is kept small, and the biasing leaf spring 6 is always in contact with the first corner 32.

[0087] As shown in Figure 13(b), when the biasing leaf spring 6 is elastically in contact with the first corner 32 and the second corner 33 (two locations), and as shown in Figure 13(c), when the biasing leaf spring 6 is elastically in contact with only the second corner 33 (one location), the pivot point S of the biasing leaf spring 6 becomes the contact point with the second corner 33. In this state (second stage), the spring constant of the biasing leaf spring 6 becomes relatively large, as shown in Figure 14, and specifically larger than in the first stage.

[0088] As shown in Figure 13(d), when the biasing leaf spring 6 elastically contacts the second corner 33 and the third corner 34 (two locations), the biasing leaf spring 6 can no longer increase the amount of deflection in the first direction, resulting in a so-called bottoming-out state.

[0089] In this example, the spring constant of the biasing leaf spring 6 changes in two stages depending on the amount of deflection of the biasing leaf spring 6 in the first direction. Specifically, the spring constant of the biasing leaf spring 6 increases from a relatively small value (first stage) to a relatively large value (second stage) as the amount of deflection of the biasing leaf spring 6 in the first direction increases.

[0090] According to the worm gear reducer 1 in this example, even when a large torque is input in reverse to the worm gear reducer 1 from a part located downstream of the worm gear reducer 1 in terms of the power transmission direction (in this example, the tire) during the operation of a mechanical device (in this example, an automobile) incorporating the worm gear reducer 1, the presence of the biasing leaf spring 6 makes it possible to efficiently suppress the generation of abnormal noise.

[0091] More specifically, by applying a large torque (including torque oscillation) in reverse to the worm gear reducer 1, the spring constant of the biasing leaf spring 6 can be set to a relatively large value (second stage) just before the amount of deflection of the biasing leaf spring 6 in the first direction increases to the state shown in Figure 13(d). Therefore, the force with which the biasing leaf spring 6 collides with the third corner portion 34 can be efficiently suppressed by the large elasticity of the biasing leaf spring 6.

[0092] Furthermore, by reversing the rotation direction of the worm 4 from the state shown in Figure 13(d), the spring constant of the biasing leaf spring 6 can be made relatively small (first stage) just before the amount of deflection of the biasing leaf spring 6 in the first direction decreases to the state shown in Figure 13(a). Therefore, the force of the collision between the wheel teeth 12 and the worm teeth 13 that occurs when the rotation direction of the worm 4 is reversed can be efficiently suppressed by reducing the biasing force of the biasing leaf spring 6.

[0093] In other words, even when the torque input in reverse to the worm gear reducer 1 results in torque oscillation, the repeated occurrence of knocking noises due to collisions between the biasing leaf spring 6 and the third corner portion 34, and tooth striking noises between the wheel teeth 12 and the worm teeth 13, i.e., the generation of rattle noise, can be efficiently suppressed.

[0094] In this example, during normal operation when no reverse torque input occurs, the deflection of the biasing leaf spring 6 in the first direction is small, so the spring constant of the biasing leaf spring 6 can be set to a relatively small value (first stage). Therefore, during normal operation, regardless of the displacement of the worm 4 due to the generation of meshing reaction forces F1 and F2, the frictional force acting on the meshing portion between the wheel teeth 12 and the worm teeth 13 can be kept small, and the torque transmission efficiency from the worm 4 to the worm wheel 3 can be sufficiently ensured.

[0095] In short, the worm gear reducer 1 in this example makes it easy to achieve a high level of both suppression of abnormal noise when torque is input in reverse and ensuring torque transmission efficiency during normal operation.

[0096] With respect to the biasing force acting on the load point P, which is the force that the biasing leaf spring 6 exerts on the support bearing 5 toward the worm wheel 3, the number of times the biasing force in the bottomed-out state shown in Figure 13(d) is set to the biasing force in the initial state shown in Figure 13(a) is arbitrary, but it is preferably set to 3 times or more.

[0097] In this example, the biasing leaf spring 6 has two corners that serve as fulcrums S, namely the first corner 32 and the second corner 33. However, when implementing this disclosure, the number of corners can be increased compared to this example, thereby changing the spring constant of the biasing leaf spring 6 in three or more stages.

[0098] When implementing this disclosure, the shape of the biasing leaf spring may be different from that of this example.

[0099] In this example, the pin 36 is made of an iron alloy, while the housing 2, including the worm housing 9, is made of an aluminum alloy. The aluminum alloy worm housing 9 has good machinability, making it easy to perform machining to form the retaining portion 21. In addition, the iron alloy pin 36 is not only readily available, but also has little effect on the spring characteristics of the biasing leaf spring 6 due to dimensional changes. Furthermore, since the biasing spring is a leaf spring, i.e., a biasing leaf spring 6, it is easy to assemble to the point of use.

[0100] The center-to-center adjustment mechanism between the worm wheel 3 and the worm 4, achieved through these combinations, can be realized with high precision, making it easier to ensure that the biasing leaf spring 6 described above performs well.

[0101] In this example, the biasing leaf spring 6 is positioned to extend in the third direction, and its entirety is located inside the worm housing 9. Therefore, as shown in Figure 5, the biasing leaf spring 6 can be assembled with one axial end of the worm housing 9 facing forward. Thus, the assembly of the biasing leaf spring 6 is easy.

[0102] Although different from the structure disclosed herein, it is also conceivable to adopt a structure in which the base and intermediate portions of the biasing leaf spring are positioned outside the worm housing, and only the tip portion of the biasing leaf spring is inserted inside the worm housing, with the tip portion pressing against the outer circumferential surface of an inner diameter side member such as a support bearing. However, in this case, it is necessary to form through holes or notches in a part of the worm housing for inserting the tip portion of the biasing leaf spring, which would increase the cost of forming such through holes or notches, and would also make it impossible to install the worm housing in locations where airtightness is required due to such through holes or notches.

[0103] Furthermore, even before installation at the intended location, there is a possibility that the portion of the biasing spring located outside the worm housing may be damaged by colliding with surrounding objects.

[0104] In contrast, in the structure of this example, the entire biasing leaf spring 6 is located inside the worm housing 9, thus avoiding all of the above-mentioned problems.

[0105] The elastic clamping means 7 clamps the support bearing 5, which corresponds to the inner diameter side member, from both sides in a third direction that is perpendicular to both the first direction, which is the biasing direction by the biasing leaf spring 6, and the second direction, which is the axial direction of the worm housing 9.

[0106] The elastic clamping means 7 has a pair of clamping leaf springs 41 positioned on both sides in the third direction of the portion between the outer circumferential surface of the support bearing 5 and the holding portion 21 provided on the inner circumferential surface of the worm housing portion 9, which corresponds to the outer diameter side member. Each clamping leaf spring 41 constituting the pair of clamping leaf springs 41 exhibits a nonlinear spring characteristic such that its spring constant increases as the amount of deflection in the third direction increases.

[0107] In this example, the elastic clamping means 7 is composed of a metal leaf spring having an overall cylindrical shape (C-shape), as shown in Figures 12(a) to 12(e). A pair of clamping leaf springs 41 constitute both circumferential sides of the elastic clamping means 7. The elastic clamping means 7 has a circumferential connecting portion 42 that connects the circumferential ends of the pair of clamping leaf springs 41 on the side closer to the worm wheel 3 in the circumferential direction. In Figure 12(a), the dashed line α indicates the boundary line between the pair of clamping leaf springs 41 and the circumferential connecting portion 42.

[0108] In this example, each clamping leaf spring 41 that makes up a pair of clamping leaf springs 41 has a first portion 43 that constitutes the circumferential middle portion and a second portion 44 that constitutes both sides in the circumferential direction. In Figure 12(a), the dashed line β indicates the boundary line between the first portion 43 and the second portion 44.

[0109] The first part 43 has a partial cylindrical shape that curves along the outer peripheral surface of the support bearing 5. Each of the second parts 44 has a partial cylindrical shape that curves along the outer peripheral surface of the support bearing 5 and is smoothly continuous with the first part 43. That is, when viewed from the axial direction of the worm 4, the circumferential ends of the radially inner surfaces of the first part 43 and the second part 44 are connected so as to have a common tangent line, and the circumferential ends of the radially outer surfaces of the first part 43 and the second part 44 are connected so as to have a common tangent line.

[0110] The radius of curvature R1 of the radially inner surface of the first part 43 in the free state is smaller than the radius of curvature Rs (see FIG. 5) of the outer peripheral surface of the support bearing 5 (R1 < Rs). The radius of curvature R2 of the radially inner surface of the second part 44 in the free state is larger than the radius of curvature R1 of the radially inner surface of the first part 43 in the free state (R2 > R1). In this example, the radius of curvature R2 is made equal to the radius of curvature Rs of the outer peripheral surface of the support bearing 5 (R2 = Rs). However, when implementing the present disclosure, the radius of curvature R2 can also be made slightly larger or smaller than the radius of curvature Rs.

[0111] In this example, in each of the clamping plate springs 41 that constitute the pair of clamping plate springs 41, residual stress is applied to the first part 43 corresponding to the portion that contacts the holding portion 21 provided on the inner peripheral surface of the worm housing portion 9. This makes it easier to ensure the durability of the first part 43, which is more likely to have a large amount of elastic deformation during operation compared to other parts. When implementing the present disclosure, the application of the residual stress can also be omitted.

[0112] The circumferential connection portion 42 has a partial cylindrical shape that curves along the outer peripheral surface of the support bearing 5 and is smoothly continuous with each of the clamping plate springs 41 that constitute the pair of clamping plate springs 41. That is, when viewed from the axial direction of the worm 4, the circumferential ends of the radially inner surfaces of the clamping plate spring 41 and the circumferential connection portion 42 are connected so as to have a common tangent line, and the circumferential ends of the radially outer surfaces of the clamping plate spring 41 and the circumferential connection portion 42 are connected so as to have a common tangent line.

[0113] In this example, the radius of curvature Rj of the radially inner surface of the circumferential connection portion 42 in the free state is made equal to the radius of curvature R2 of the radially inner surface of the second portion 44 in the free state (Rj = R2).

[0114] When implementing this disclosure, the circumferential connection portion can be omitted, that is, the pair of clamping leaf springs 41 can be separated from each other.

[0115] In this example, the elastic clamping means 7 has a circumferential positioning piece 45 that engages with the worm housing 9 in the circumferential direction.

[0116] In this example, two circumferential positioning pieces 45 are provided at circumferential intervals of the circumferential connection portion 42. The two circumferential positioning pieces 45 are provided so as to protrude radially outward from the circumferential interval of the circumferential connection portion 42.

[0117] More specifically, the two circumferential positioning pieces 45 are formed by bending a pair of tongue-shaped pieces radially outward, which are provided by forming an H-shaped through-hole in the circumferential middle portion of the circumferential connection portion 42. The circumferential positioning pieces 45 are the parts that circumferentially position and prevent rotation of the elastic clamping means 7 by engaging with the locking portion 25 of the holding portion 21 in the circumferential direction.

[0118] When implementing this disclosure, if circumferential positioning pieces are provided, the shape, number, and circumferential position of the circumferential positioning pieces may differ from those in this example. Furthermore, the circumferential positioning pieces may be provided to engage in the circumferential direction with an inner diameter side member which consists of a support bearing or an outer fitting member fitted onto the support bearing.

[0119] In this example, the circumferential connection portion 42 has a low-rigidity portion 57 in its circumferential intermediate portion, specifically the portion between the two circumferential positioning pieces 45, which is less rigid than the circumferential sides of the remaining circumferential connection portion 42 and the pair of clamping leaf springs 41. In this example, in order to reduce the rigidity of the low-rigidity portion 57, a rectangular through-hole 58 is formed in the circumferential portion where the low-rigidity portion 57 is located, thereby reducing the section modulus of the circumferential portion. The low-rigidity portion 57 is provided to reduce the interaction of the pair of clamping leaf springs 41 by lowering the deflection resistance of the low-rigidity portion 57.

[0120] When implementing this disclosure, if a low-rigidity section is provided at the circumferential connection, the low-rigidity section may be provided at a different circumferential location than in this example, at multiple locations spaced apart in the circumferential direction, or along the entire length in the circumferential direction. When implementing this disclosure, it is also possible to omit providing a low-rigidity section at the circumferential connection.

[0121] When implementing this disclosure, different means than those used in this example may be employed to reduce the rigidity of the low-rigidity part, such as reducing the thickness of the plate in the low-rigidity part.

[0122] In this example, the elastic clamping means 7 has an axial positioning piece 46 that engages with the support bearing 5 in the axial direction.

[0123] In this example, two axial positioning pieces 46 are provided on each of the pair of clamping leaf springs 41, spaced apart in the circumferential direction. More specifically, the axial positioning pieces 46 are provided so as to bend radially inward from one end of the axial direction of the circumferential middle portion of each of the second parts 44.

[0124] When implementing this disclosure, if axial positioning pieces are provided, the shape, number, circumferential position, and axial position of the axial positioning pieces may differ from those in this example. Furthermore, the axial positioning pieces may be provided to engage in the axial direction with an inner diameter side member, which consists of a worm housing or an internal fitting member fitted into the worm housing.

[0125] As shown in Figure 5, the elastic clamping means 7 is positioned between the outer circumferential surface of the support bearing 5 and the retaining portion 21 provided on the inner circumferential surface of the worm housing 9. Specifically, the elastic clamping means 7 is fitted onto the support bearing 5 and positioned inside the main retaining portion 23 that constitutes the retaining portion 21.

[0126] In this state, the two circumferential positioning pieces 45 provided on the elastic clamping means 7 are positioned inside the locking portion 25 that constitutes the holding portion 21, thereby engaging with the locking portion 25 in the circumferential direction. As a result, the elastic clamping means 7 is positioned in the circumferential direction, and the pair of clamping leaf springs 41 that constitute the elastic clamping means 7 are positioned on both sides in the third direction of the portion between the outer circumferential surface of the support bearing 5 and the main holding portion 23.

[0127] In this example, a gap in a first direction and a gap in a third direction are provided between the two circumferential positioning pieces 45 and the locking portion 25. This allows for slight displacement of the two circumferential positioning pieces 45 relative to the locking portion 25 in the first and third directions, which is necessary during operation.

[0128] In this example, the dimensions of the two circumferential positioning pieces 45 in the first direction are set such that, regardless of whether the elastic clamping means 7 moves in the first direction together with the tip of the worm 4 and the support bearing 5 during operation, sufficient penetration of the two circumferential positioning pieces 45 into the locking portion 25 is always ensured.

[0129] Each of the axial positioning pieces 46 provided on the elastic clamping means 7 engages with the outer ring 18 of the support bearing 5 in the axial direction by contacting one axial side surface of the outer ring 18. This positions the elastic clamping means 7 in the axial direction relative to the support bearing 5.

[0130] Furthermore, each of the clamping leaf springs 41 constituting the pair of clamping leaf springs 41 is positioned relative to the surrounding portion as follows, with the meshing reaction forces F1 and F2 being zero.

[0131] The circumferential center of the radially outer surface of the first part 43 is in contact with the planar portion 26 constituting the main holding portion 23 at point Q1 shown in Figure 15(a). The circumferential outer ends of each radially inner surface of the second part 44, that is, the ends of the second part 44 furthest from the first part 43 in the circumferential direction, are in contact with the outer circumferential surface of the support bearing 5 at point Q2 shown in Figure 15(a). The radially inner surface of the first part 43 is not in contact with the outer circumferential surface of the support bearing 5, and a gap exists between the radially inner surface of the first part 43 and the outer circumferential surface of the support bearing 5.

[0132] Each radially outer surface of the second part 44 does not contact the main holding part 23, and a gap exists between each radially outer surface of the second part 44 and the main holding part 23. In other words, the clamping leaf spring 41 is in contact with the main holding part 23 at only one point (point Q1 shown in Figure 15(a)) and with the outer circumferential surface of the support bearing 5 at only two points (point Q2 shown in Figure 15(a)).

[0133] With the meshing reaction forces F1 and F2 at zero, each of the clamping leaf springs 41 constituting the pair of clamping leaf springs 41 experiences an initial deflection in a third direction. This suppresses rattling of the support bearing 5 in the third direction inside the main holding portion 23, even when the meshing reaction forces F1 and F2 are at zero. However, from the viewpoint of minimizing the frictional force of the pair of clamping leaf springs 41 against the flat portion 26 when the meshing reaction forces F1 and F2 are at zero, it is preferable to set the initial deflection in the third direction to be as small as possible.

[0134] Of the pair of clamping leaf springs 41, the second portion 44 of the clamping leaf spring 41 located on the other side (left side in Figure 5) with respect to the third direction, the portion furthest from the worm wheel 3, intersects with a radial line L1 containing the vector of the meshing reaction force F1 when viewed from the second direction. Of the pair of clamping leaf springs 41, the second portion 44 of the clamping leaf spring 41 located on one side (right side in Figure 5) with respect to the third direction, the portion furthest from the worm wheel 3, intersects with a radial line L2 containing the vector of the meshing reaction force F2 when viewed from the second direction.

[0135] In the above state, the elastic clamping means 7 clamps the support bearing 5 from both sides in the third direction with a pair of clamping leaf springs 41. This suppresses the momentum when the tip of the worm 4 moves in the third direction, thereby suppressing the generation of abnormal noise.

[0136] In this example, the main holding portion 23, which is positioned around the support bearing 5, is formed to be slightly larger than the outer circumferential surface of the support bearing 5, in order to allow the tip of the worm 4 to move toward and away from the worm wheel 3 in a first direction. As a result, the tip of the worm 4 can also move in a third direction.

[0137] On the other hand, the meshing reaction forces F1 and F2 acting on the worm 4 include not only a component in the first direction but also a force in the third direction. The direction of this third-direction component reverses according to the rotation direction of the worm 4. Therefore, if the tip of the worm 4 is allowed to move in the third direction without resistance, the third-direction component of the meshing reaction forces F1 and F2 acting on the worm 4 causes the outer circumferential surface of the support bearing 5 to collide forcefully with the main holding portion 23 in the third direction, making it easy for unpleasant noises such as knocking and rattling to occur.

[0138] In this example, to suppress the generation of such abnormal noises, the support bearing 5 is clamped from both sides in the third direction by a pair of clamping leaf springs 41 that constitute the elastic clamping means 7. This suppresses the generation of abnormal noises by reducing the momentum when the tip of the worm 4 moves in the third direction.

[0139] In this example, when the meshing reaction force F1 or F2 applied to the tip of the worm 4 increases, the pressing force in the third direction acting on the clamping leaf spring 41 located on one side (left side in Figure 5) or the other side (right side in Figure 5) of the support bearing 5 in the third direction increases. As a result, the amount of deflection of the clamping leaf spring 41 in the third direction increases. Figures 15(a) to 15(c) schematically show how this amount of deflection increases.

[0140] In this example, as the amount of deflection of the clamping leaf spring 41 in the third direction increases, the distance W in the first direction between the contact points (point Q2) of the radially inner surfaces of the two second parts 44 with respect to the outer circumferential surface of the support bearing 5 decreases continuously, as shown in Figures 15(a) to 15(c). As shown in Figure 15(c), when the first part 43 of the clamping leaf spring 41 is sandwiched between the flat part 26 of the main holding part 23 and the outer circumferential surface of the support bearing 5, the clamping leaf spring 41 can no longer increase the amount of deflection in the third direction, resulting in a so-called bottoming-out state.

[0141] In this example, as the amount of deflection of the clamping leaf spring 41 in the third direction increases, the distance W decreases continuously until the bottoming-out state is reached. As a result, the spring constant of the clamping leaf spring 41 increases continuously, as shown in Figure 16 (conceptual diagram).

[0142] Therefore, the biasing action of the tip of the worm 4 and the support bearing 5 by the biasing leaf spring 6 can be made smoother, and the force of collisions between members in the third direction around the tip of the worm 4 can be easily suppressed.

[0143] In other words, the spring constant of the clamping leaf spring 41 decreases when the amount of deflection in the third direction is small (low load region). Therefore, in this stage, the frictional force acting between the clamping leaf spring 41 and the flat portion 26 of the main holding portion 23, and the frictional force acting between the clamping leaf spring 41 and the outer surface of the support bearing 5, decreases. As a result, the movement of the tip of the worm 4 and the support bearing 5 in the first direction can be made smoother. Consequently, the biasing operation of the tip of the worm 4 and the support bearing 5 by the biasing leaf spring 6 can be made smoother.

[0144] On the other hand, the spring constant of the clamping leaf spring 41 increases when the amount of deflection in the third direction becomes large (high load region). Therefore, the momentum of the movement of the support bearing 5 in the third direction just before bottoming out as shown in Figure 15(c) can be efficiently suppressed by the large elasticity of the clamping leaf spring 41. This effectively suppresses the generation of collision noise when bottoming out occurs.

[0145] Furthermore, by reversing the rotation direction of the worm 4 from the state shown in Figure 15(c), the spring constant of the clamping leaf spring 41 can be reduced just before the amount of deflection of the clamping leaf spring 41 in the third direction decreases to the state shown in Figure 15(a). Therefore, the force of the collision between the wheel teeth 12 and the worm teeth 13 that occurs when the rotation direction of the worm 4 is reversed can be efficiently suppressed by reducing the biasing force of the clamping leaf spring 41. This makes it possible to efficiently suppress the generation of tooth-clack noise between the wheel teeth 12 and the worm teeth 13.

[0146] In this example, the radius of curvature of the radially inner surface of the second portion 44, which constitutes both circumferential sides of the clamping leaf spring 41, is set to a constant size. However, when implementing this disclosure, the radius of curvature of the radially inner surface of the second portion can be changed in steps or continuously with respect to the circumferential direction.

[0147] In this example, the portion of the main holding part 23 that elastically contacts each of the pair of clamping leaf springs 41 is composed of a planar portion 26 that extends in the first direction. Therefore, as shown in Figures 17(a) to 17(c), even when the elastic clamping means 7 moves in the first direction, the amount of deflection of the pair of clamping leaf springs 41 in the third direction, i.e., the spacing W, does not change, and the spring constant of each of the clamping leaf springs 41 that make up the pair of clamping leaf springs 41 can be kept constant. Thus, stable spring characteristics can be ensured for the biasing leaf spring 6 and the elastic clamping means 7.

[0148] When implementing this disclosure, the length of the pair of planar portions 26 in the first direction can be made smaller than the stroke amount that the elastic clamping means 7 can move in the first direction together with the tip of the worm 4 and the support bearing 5 during operation. In other words, when a large meshing reaction force is applied to the worm 4, the elastic contact portion of the clamping leaf spring 41 with respect to the main holding portion 23 can move from the planar portion 26 to the cylindrical surface portion 27. Even in this case, the spring constant of the clamping leaf spring 41 can be kept constant as long as the contact portion is on the planar portion 26.

[0149] In this example, when viewed from the second direction, the radial lines L1 and L2 containing the vectors of the meshing reaction forces F1 and F2 intersect a portion of the circumferential direction of the cylindrical surface portion 27 of the main holding portion 23. Also, of the pair of clamping leaf springs 41, the second portion 44 of the clamping leaf spring 41 located on the other side (left side in Figure 5) with respect to the third direction, which is farther from the worm wheel 3, intersects the radial line L1 containing the vector of the meshing reaction force F1 when viewed from the second direction.

[0150] Furthermore, of the pair of clamping leaf springs 41, the second portion 44 of the clamping leaf spring 41 located on one side (the right side in Figure 5) with respect to the third direction, the portion furthest from the worm wheel 3, intersects with the radial line L2 containing the vector of the meshing reaction force F2 when viewed from the second direction.

[0151] Therefore, even if the support bearing 5 tends to move in the direction of the meshing reaction force F1 during operation, the momentum of this movement can be suppressed by the elasticity of the second portion 44 of the clamping leaf spring 41, which is located on one side with respect to the third direction and is furthest from the worm wheel 3. Furthermore, the meshing reaction force F1 can be supported by the cylindrical surface portion 27 of the main holding portion 23.

[0152] Even if the support bearing 5 tends to move in the direction of the meshing reaction force F2 during operation, the momentum of this movement can be suppressed by the elasticity of the second portion 44 of the clamping leaf spring 41, which is located on the other side with respect to the third direction and is furthest from the worm wheel 3. Furthermore, the meshing reaction force F2 can be supported by the cylindrical surface portion 27 of the main holding portion 23.

[0153] In this example, as shown in Figure 5, the cylindrical surface portion 27 of the main holding portion 23 is located in a circumferential range where it can intersect with radial lines L1 and L2 containing the vectors of the meshing reaction forces F1 and F2 when viewed from the second direction. However, the inclination angle of radial line L2 with respect to the third direction is smaller than the inclination angle of radial line L1 with respect to the third direction. Therefore, the circumferential edge portion E2 of the cylindrical surface portion 27 on the radial line L2 side (right side in Figure 5) with respect to the third direction can be positioned closer to the worm wheel 3 with respect to the first direction (lower side in Figure 5) than the circumferential edge portion E1 on the radial line L1 side (left side in Figure 5).

[0154] Therefore, in the sub-retaining portion 24 that protrudes outward from the end of the main retaining portion 23 that is furthest from the worm wheel 3 in the first direction (upper side in Figures 5 and 8), the large recess 28, which is the part where one end of the biasing leaf spring 6 and the pin 36 are located, is positioned in the third direction on the same side as the radial line L2 (right side in Figure 5) as the central axis of the worm 4.

[0155] This allows the large recess 28 to be positioned closer to the worm wheel 3 in the first direction compared to when the large recess 28 is positioned on the same side as the radial line L1 in the third direction (left side in Figure 5). In other words, by adopting this arrangement, the width dimension of the entire holding portion 21, including the main holding portion 23 and the sub-holding portion 24, in the first direction can be minimized.

[0156] When implementing this disclosure, the spring characteristics of each clamping leaf spring constituting a pair of clamping leaf springs may be linear.

[0157] In the structure of this example, a biasing plate spring 6 that biases the support bearing 5 toward the worm wheel 3 in the first direction and elastic clamping means 7 that clamp the support bearing 5 from both sides in the third direction are formed as separate components from each other. Therefore, unlike the case where the biasing plate spring and the elastic clamping means are formed as an integral component with each other, the spring characteristics of each of the biasing plate spring 6 and the elastic clamping means 7 can be set without interfering with each other. Accordingly, the degree of freedom in the design of the biasing plate spring 6 and the elastic clamping means 7 can be increased.

[0158] (2) Electric power steering apparatus As shown in FIG. 1, the electric power steering apparatus 48 of this example includes a steering wheel 49, a steering shaft 50, a steering column 51, a pair of universal joints 52a and 52b, an intermediate shaft 53, a steering gear unit 54, and the worm reducer 1 and the electric motor 11 of this example.

[0159] The steering wheel 49 is supported and fixed to the rear end portion of the steering shaft 50. The steering shaft 50 is rotatably supported inside the steering column 51 supported by the vehicle body. The front end portion of the steering shaft 50 is connected to the pinion shaft 55 of the steering gear unit 54 via the rear universal joint 52a, the intermediate shaft 53, and the front universal joint 52b.

[0160] Therefore, when the driver rotates the steering wheel 49, the rotation of the steering wheel 49 is transmitted to the pinion shaft 55 via the steering shaft 50, the pair of universal joints 52a and 52b, and the intermediate shaft 53. The rotation of the pinion shaft 55 is converted into a linear motion of a rack shaft (not shown) of the steering gear unit 54 that meshes with the pinion shaft 55. As a result, when the pair of tie rods 56 are pushed and pulled, a steering angle corresponding to the amount of rotation operation of the steering wheel 49 is imparted to the left and right steering wheels.

[0161] In this example, the electric power steering system 48 is configured to reduce the force required for the driver to operate the steering wheel 49 by increasing the auxiliary power of the electric motor 11 using a worm reducer 1 before applying it to the front end of the steering shaft 50.

[0162] When implementing this disclosure, the worm reducer 1 and the electric motor 11 can also be positioned to provide auxiliary power to the pinion shaft or rack shaft of the steering gear unit.

[0163] [Example 2] A second example of the embodiment of this disclosure will be described with reference to Figure 18.

[0164] In this example, the portion of the sub-holding part 24a that elastically contacts the biasing leaf spring 6 is a convex curved surface portion 37. In the structure of this example, which employs this configuration, as the amount of deflection of the biasing leaf spring 6 in the first direction increases, the biasing leaf spring 6 curves along the convex curved surface portion 37. Therefore, the position of the pivot point S of the biasing leaf spring 6 can be continuously changed in the direction approaching the load point P, and the spring constant of the biasing leaf spring 6 can be continuously, specifically quadratically, increased.

[0165] The other components and effects of the second example are the same as those of the first example.

[0166] This disclosure can be implemented by appropriately combining the structures of each example of the embodiments of this disclosure described above, to the extent that no inconsistencies arise. [Explanation of symbols]

[0167] 1. Worm gear reducer 2 Housing 3 Worm Wheels 4 Warm 5 Support bearings 6. Biased leaf spring 7 Elastic clamping means 8 Wheel housing 9. Worm containment section 10 Lid 11 Electric motor 12 Wheel Teeth 13 Warm teeth 14 Ball bearings 15 Output shaft 16 Couplings 17 Inner circle 18 Outer ring 19 balls 20 Small diameter cylindrical surface part 21 Holding part 22 Step surface 23 Main holding part 24, 24a Sub holding part 25 Locking part 26 Plane section 27 Cylindrical surface part 28 Large recess 29 Small recesses 30 First slope section 31 2nd slope section 32 1st corner 33 Second corner 34 Third corner 35 recess 36 pins 37 Convex curved part 38 Band part 39 Circuit board section 40 Folded plate section 41 Clamping leaf spring 42 Circumferential connection section 43 Part 1 44 Part 2 45 Circumferential positioning piece 46 Axial positioning piece 47 Retaining ring 48 Electric power steering system 49 Steering Wheel 50 Steering shaft 51 Steering column 52a, 52b Universal joint 53 Intermediate shaft 54 Steering Gear Unit 55 Pinion shaft 56 Tie Rod 57 Low rigidity part 58 Through-pores

Claims

1. A housing comprising a wheel housing portion and a worm housing portion having a central axis that is twisted relative to the central axis of the wheel housing portion, and whose axial intermediate portion opens into the wheel housing portion, A worm wheel having wheel teeth on its outer circumference and rotatably supported inside the wheel housing, A worm having worm teeth on its outer circumferential surface that mesh with the wheel teeth, and a worm rotatably supported inside the worm housing, A support bearing fitted onto the tip of the worm, A biasing leaf spring biases the inner diameter side member, which is the support bearing or an outer fitting member fitted onto the support bearing, toward the worm wheel side, Equipped with, The biasing leaf spring is, The portion between the outer circumferential surface of the inner diameter side member and the inner circumferential surface of the outer diameter side member, which is the worm housing or an internal fitting member fitted into the worm housing, is arranged on the side furthest from the worm wheel with respect to the first direction, which is the biasing direction by the biasing leaf spring. The inner diameter side member has a load point which is the contact portion with the outer circumferential surface, and the outer diameter side member has a fulcrum which is the portion of the contact portion with the inner circumferential surface that is closest to the load point, and The spring exhibits nonlinear spring characteristics such that the spring constant increases as the amount of deflection in the first direction increases, causing the position of the support point to move closer to the load point. Worm gear reducer.

2. The worm gear reducer according to claim 1, wherein the biasing leaf spring is arranged to extend in a third direction perpendicular to both the first direction and the second direction which is the axial direction of the worm housing, with one end of the biasing leaf spring in the third direction cantilevered to the outer diameter side member, and the other end of the biasing leaf spring in the third direction having the load point.

3. The worm gear reducer according to claim 2, wherein one end of the biasing leaf spring is cantilevered to the outer diameter side member using a pin arranged to extend in the second direction.

4. The worm gear reducer according to claim 3, wherein the outer diameter side member is made of an aluminum alloy and the pin is made of an iron alloy.

5. The inner circumferential surface of the outer diameter side member has a main holding portion and a sub-holding portion, The main holding portion is slightly larger than the outer circumferential surface of the inner diameter side member, and the inner diameter side member is positioned inside it. The sub-retaining portion extends outward from the end of the main retaining portion that is furthest from the worm wheel in the first direction, and the biasing leaf spring is arranged on its inner side. The main holding portion is located in a circumferential range such that, when viewed from a second direction, it intersects with a radial line L1 that includes the vector of the meshing reaction force F1 applied to the worm from the meshing portion between the worm teeth and the wheel teeth when the worm rotates in a predetermined direction, and also intersects with a radial line L2 that includes the vector of the meshing reaction force F2 applied to the worm from the meshing portion when the worm rotates in a direction opposite to the predetermined direction. The inclination angle of the radial line L2 with respect to the third direction is smaller than the inclination angle of the radial line L1 with respect to the third direction. Of the sub-retaining portion, the portion where one end of the biasing leaf spring is located is positioned on the same side as the radial line L2 as the central axis of the worm in the third direction. The worm gear reducer according to claim 2.

6. The worm gear reducer according to claim 2, wherein the outer diameter side member has a plurality of corners arranged spaced apart in the third direction as portions that come into contact with the biasing leaf spring during operation.

7. The worm gear reducer according to claim 6, wherein the biasing leaf spring is configured to be able to contact two or more of the multiple corners simultaneously during operation.

8. The worm gear reducer according to claim 2, wherein the outer diameter side member has a convex curved surface portion that contacts the biasing leaf spring during operation.

9. The inner diameter side member is provided with elastic clamping means that clamps it from both sides in a third direction that is perpendicular to both the first direction and the second direction which is the axial direction of the worm housing, The elastic clamping means has a pair of clamping leaf springs arranged on both sides in the third direction of the portion between the outer circumferential surface of the inner diameter side member and the inner circumferential surface of the outer diameter side member. Each of the clamping leaf springs constituting the pair exhibits a nonlinear spring characteristic such that its spring constant increases as the amount of deflection in the third direction increases. A worm gear reducer according to any one of claims 1 to 8.

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