Abstract: A recirculating ball power steering system includes an electric motor. The system also includes a ball screw rotatably driven by the electric motor. The system further includes a ball nut translatable along the ball screw in a linear direction during rotation of the ball screw. The system yet further includes a sliding joint in sliding contact with an outer surface of the ball nut, the sliding joint moveable in a non-parallel direction relative to the linear direction of the ball nut.

Abstract: A steering column assembly includes a steering column shaft having a first end and a second end. The steering column assembly also includes an intermediate shaft coupled to the steering column shaft first end. The steering column assembly further includes a steering input pinion coupled to the intermediate shaft. The steering column assembly yet further includes a counter rotation mechanism causing a non-rotational condition of at least a portion of the steering shaft via counter rotational movement of the steering column assembly during rotation of the steering input pinion.

Abstract: A torsion bar is provided that is easy, quick, and cost effective to manufacture. The torsion bar may extend along an axis and have a first end and a second end that is spaced from the first end. The torsion bar may have an active section positioned between the first and second ends. The active section may also have a length defined along the axis. A cross-section transverse to the axis may define a contour of the torsion bar where the contour may be uniform along the length of the active section. The contour may define at least one of a polygon and a polygon-like shape.

Abstract: An interconnect assembly includes a main body being formed of flexible material and extending between a first end and a second end, the main body having a thickness defined by a top surface and a bottom surface. The interconnect assembly also includes a first connection port located proximate the first end. The interconnect assembly further includes a second connection port located proximate the second end. The interconnect assembly yet further includes a copper trace having a first contact and a second contact, the first contact disposed on the top surface and located adjacent to the first connection port, and the second contact located on the top surface and adjacent to the second connection port.

Abstract: A position measurement system for a steering system includes a steering shaft. The position measurement system also includes a worm gear coupled to the steering shaft. The position measurement system further includes a worm in meshed engagement with the worm gear, the worm driven by a motor. The position measurement system yet further includes a first sensor operatively coupled to the worm to detect an angular position of the worm and the motor that drives the worm. The position measurement system also includes a driving gear coupled to the steering shaft. The position measurement system further includes a spur gear in meshed engagement with the driving gear. The position measurement system yet further includes a second sensor operatively coupled to the spur gear to detect an angular position of the spur gear.

Abstract: A method of manufacturing a torsion bar is provided. The method includes cutting a stock torsion bar material to a desired torsion bar length to form the torsion bar. The method also includes forming a first end portion by removing material from the torsion bar to form a first annular groove extending circumferentially about the torsion bar. The method further includes forming a second end portion by removing material from the torsion bar to form a second annular groove extending circumferentially about the torsion bar.

Abstract: A torsion bar includes a central portion extending in an axial direction about a longitudinal axis. The torsion bar also includes a first end portion having a splined outer surface, the first end portion disposed proximate a first end of the torsion bar, the first end portion spaced from the central portion with a first annular groove extending circumferentially about the torsion bar.

Abstract: A stator for a vehicle includes a body defining a central bore that is adapted to receive a rotor. The stator also includes a plurality of electrical conductors radially disposed on the body. Each of respective electrical conduction of the plurality of electrical conductors includes a corresponding magnetic code wound in a conductive wire. The stator also includes a wired frame that includes one or more conductive wires. Each of the one or more conductive wires includes a first end and a second end opposite the first end. Each respective first end of the one or more conductive wires is connected to corresponding terminals of the stator. Each respective second end of the one or more conductive wires is bent at an angle and adapted to mate with a controller.

Abstract: A remote sensor for a vehicle includes a first retaining cup disposed on a first end of the remote sensor. The remote sensor also includes a second retaining cup disposed proximate the first retaining cup, the second retaining cup being configured to mate with the first retaining cup. The remote sensor also includes a sensing device disposed in an aperture defined by the second retaining cup, the sensing device being configured to measure at least one characteristic of the vehicle. The remote sensor also includes a flex PCB having a first end connected to the sensing device and a second end connected or coupled to a controller of the vehicle, wherein at least a portion of the first end of the flex PCB is retained by the first retaining cup and the second retaining cup.

Abstract: A power steering system including a first linkage arm pivotally coupled to a cross-link member extending in a transverse direction. Also included is a first shaft generally orthogonal to the first linkage arm, the first shaft configured to rotate the first linkage arm. Further included is a power portion of the first linkage arm extending from a first end of the first linkage arm to the first shaft. Yet further included is an assist portion of the first linkage arm extending from the first shaft to a second end of the first linkage arm. Also included is an electric actuator. Further included is a linkage member extending from the electric actuator and operatively coupled to the assist portion of the first linkage arm.

Abstract: A method of assembling an electric power steering assembly includes providing a shaft that extends along a longitudinal axis between a first shaft end and a second shaft end. The method further includes extruding or drawing the shaft through a die to define a spline that extends between the first shaft end and the second shaft end. The spline includes a first tooth having a first tip. The method still further includes applying a sleeve over a portion of the spline, such that the sleeve extends from the second shaft end towards the first shaft end.

Abstract: A method of assembling an electric power steering assembly includes providing a shaft that extends along a longitudinal axis between a first shaft end and a second shaft end. The method further includes extruding or drawing the shaft through a die to define a spline that extends between the first shaft end and the second shaft end. The spline includes a first tooth having a first tip. The method still further includes applying a sleeve over a portion of the spline, such that the sleeve extends from the second shaft end towards the first shaft end.

Abstract: A steering system includes a tie rod and an actuator assembly. The tie rod is movably disposed within a tie rod housing. The actuator assembly includes a first member and a second member. The first member extends from an actuator. The second member has a second member first end operatively connected to the first member and a second member second end operatively connected to the tie rod. The second member first end is arranged to translate the tie rod along a first axis responsive to the actuator moving the second member first end relative to a second axis.

Abstract: A steering column assembly includes a steering column shaft having a first end and a second end. The steering column assembly also includes an intermediate shaft coupled to the steering column shaft first end. The steering column assembly further includes a steering input pinion coupled to the intermediate shaft. The steering column assembly yet further includes a counter rotation mechanism causing a non-rotational condition of at least a portion of the steering shaft via counter rotational movement of the steering column assembly during rotation of the steering input pinion.

Abstract: A steering column assembly configured to couple to a steering wheel is provided. The assembly includes a steering column shaft having a first end and a second end, the second end configured to couple to the steering wheel. The assembly also includes an intermediate shaft coupled to the steering column shaft first end. The assembly further includes a steering input pinion coupled to the intermediate shaft. The assembly yet further includes a counter rotation mechanism configured to counter rotate rotational movement of the steering column assembly such that the steering wheel does not rotate.

Abstract: A human exoskeleton includes a power source. The human exoskeleton also includes a controller configured to activate power between the exoskeleton and the power source. The human exoskeleton further includes a power disconnect mechanism electronically connected to the controller and configured to disconnect power between the exoskeleton and the power source when activated, the power disconnect mechanism activated when a pressure applied to the power disconnect mechanism is above a range programmed in the controller or below the range programmed in the controller, the human exoskeleton powered only when the pressure applied to the power disconnect mechanism is within the range programmed in the controller.

Abstract: A human exoskeleton is provided and includes a power source. The human exoskeleton also includes a controller configured to activate power between the exoskeleton and the power source. The human exoskeleton further includes a power disconnect mechanism electronically connected to the controller and configured to disconnect power between the exoskeleton and the battery when activated, the power disconnect mechanism physically in contact with a wearer of the human exoskeleton.

Abstract: A torsion bar includes a central portion extending in an axial direction about a longitudinal axis. The torsion bar also includes a first end portion having a splined outer surface, the first end portion disposed proximate a first end of the torsion bar, the first end portion spaced from the central portion with a first annular groove extending circumferentially about the torsion bar.

Abstract: A brushless motor assembly includes a housing, a cover assembly, an insert, and a sensor assembly. The housing is disposed about a motor. The cover assembly is disposed on the housing and has a base and a connecting portion. The connecting portion defines a connecting region. The insert has a first insert surface and a second insert surface disposed opposite the first insert surface, each extending between a first insert end and a second insert end. The sensor assembly is disposed on the second insert surface.

Abstract: In one aspect of the invention, a torsion bar assembly is provided. The assembly includes a first shaft having a first bore, a second shaft having a second bore, the second shaft operatively coupled to the first shaft, and a torsion bar positioned within the first and second bores. The torsion bar includes a splined first end having a first diameter extending to a first end face having a diameter generally the same as the first diameter, a splined second end having a second diameter extending to a second end face having a diameter generally the same as the second diameter, and an active diameter extending between the splined first end and the splined second end. The torsion bar is fabricated from a material having a hardness greater than 45 Rockwell C-Scale.