Disk Coupling for Electric Power Steering Motor Worm Deviation
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Solution Overview
Problem
Existing electric power steering systems face challenges with direct spline connections between the electric machine and worm, which fail to effectively compensate for radial and axial deviations, leading to abnormal noises and wear due to excessive drive gaps and improper meshing.
Innovation Solution
The proposed solution involves using multiple disks with through-holes and bolts between the electric machine and worm mounting flanges, allowing for radial and axial deviation compensation through elastic adjustment, thereby eliminating abnormal noises and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If direct spline connection is used between electric machine shaft and worm shaft, then the structure is simple, but radial deviation and axial deviation cannot be compensated, resulting in excessive drive gap and abnormal noises
Solution Approach 1:
A disk is introduced as an intermediary component between the electric machine shaft and the worm shaft. The disk includes a first connection portion connected to the electric machine shaft and a second connection portion connected to the worm shaft, serving as a mediator that enables deviation compensation while maintaining structural simplicity
Solution Approach 2:
The connection parameters between shafts are made adjustable through the disk structure. The disk allows radial and axial position parameters to be changed to compensate for deviations, transforming fixed parameters into adjustable ones to achieve proper meshing
2Manufacturing precision
If plastic coupling connection is used between electric machine shaft and worm shaft, then radial deviation can be compensated to a certain extent, but axial deviation cannot be compensated
Solution Approach 1:
The disk structure performs multiple functions simultaneously: it connects the two shafts, compensates for radial deviation through its radial positioning capability, and compensates for axial deviation through its axial positioning capability. This multi-functional design overcomes the limitation of plastic couplings that only handle radial deviation
3Reliability
If disk is provided between electric machine shaft and worm shaft, then deviation compensation is improved, but the structure becomes more complex
Solution Approach 1:
The connection structure is segmented into distinct functional portions: the disk body and the first connection portion (to electric machine shaft) and second connection portion (to worm shaft). This segmentation allows each portion to be optimized independently while maintaining overall simplicity through modular design
Data Source
Figure 1
AI summary
The present invention provides an apparatus for connecting an electric machine and a worm for an electric power steering system, comprising an electric machine (1), an electric machine shaft (2) connected to the electric machine (1), and a worm (3), wherein an end of the electric machine shaft (2) is provided with a first mounting flange (5), and an end of the worm (3) is provided with a second mounting flange (6). The apparatus for connecting an electric machine and a worm is characterized in that at least one disk (4) is provided between the first mounting flange (5) of the electric machine shaft (2) and the second mounting flange (6) of the worm (3). The apparatus for connecting an electric machine and a worm for an electric power steering system provided in the present invention is structurally simple, and at the same time as transferring electric machine torque with high efficiency, can effectively compensate for radial deviation and axial deviation between the electric machine shaft and a worm shaft.