Abstract: An electric power steering system includes a system housing, an electric motor, a steering shaft assembly, and an electronic control unit. The electric motor is disposed within a motor housing that is disposed within and is attached to the system housing. The steering shaft assembly has a torsion bar that that extends at least partially through the system housing and motor housing. The electronic control unit a printed circuit board and a torque sensor. The printed circuit board is disposed within and is attached to the system housing. The torque sensor is disposed on the printed circuit board and is arranged to provide a signal indicative of angular displacement of the torsion bar.

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 column assembly is provided. The assembly includes a column shaft rotatable about an axis and configured to couple to a steering wheel rim and a hub support configured to be non-rotatably coupled to a support structure of the vehicle. A stationary hub is coupled to the hub support, the steering wheel rim being rotatable relative to the stationary hub.

Abstract: A pulley assembly including a drive pulley, a driven pulley, a flexible belt configured to connect the drive pulley to the driven pulley, an idler including a bearing and an idler pulley, the idler pulley engaged with the belt, the idler rotating about a first longitudinal axis, and an axial trap within the pulley assembly configured to restrict longitudinal movement of the idler along the first longitudinal axis.

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 power assist system includes a motor having a rotor shaft, a drive pulley attached to the rotor shaft, a driven pulley, a flexible belt configured to connect the drive pulley to the driven pulley, and a ball screw assembly. The ball screw assembly includes a rotatable ball screw rotatable with the driven pulley, a linearly translated ball nut surrounding the ball screw, and an anti-rotation device arranged to prevent rotation of the ball nut.

Abstract: An electric power steering system includes a system housing, an electric motor, a steering shaft assembly, and an electronic control unit. The electric motor is disposed within a motor housing that is disposed within and is attached to the system housing. The steering shaft assembly has a torsion bar that that extends at least partially through the system housing and motor housing. The electronic control unit a printed circuit board and a torque sensor. The printed circuit board is disposed within and is attached to the system housing. The torque sensor is disposed on the printed circuit board and is arranged to provide a signal indicative of angular displacement of 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: 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: An assembly includes a steering shaft and a primary drive system eccentrically coupled to the steering shaft and configured to transfer a torque applied to the steering shaft to a vehicle steering system. The assembly also includes a secondary drive system coupled to the steering shaft and configured to transfer the torque applied to the steering shaft if the primary drive system is inactive and substantially unable to transfer the torque.

Abstract: A power steering system includes 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 and configured to rotate the first linkage arm. Further included is a second linkage arm pivotally coupled to the cross-link member with a pivot location. The power steering system yet further includes an electric actuator. Also included is a linkage member extending from the electric actuator and operatively coupled to an assist portion of the second linkage arm to reduce the steering effort required by a driver of the vehicle.

Abstract: A ball screw assembly includes a helical path for a plurality of balls to be routed through, the helical path extending from a first end to a second end. The ball screw assembly also includes a recirculation path extending from a first transition location to a second transition location. The recirculation path includes a first segment defined by a first arc portion of a first ellipse. The recirculation path also includes a second segment defined by a second arc portion of the first ellipse. The recirculation path further includes a third segment defined by an arc of a second ellipse, wherein the first ellipse and the second ellipse are disposed in a common plane.

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.

Abstract: A steering column assembly is provided. The assembly includes a column shaft rotatable about an axis and configured to couple to a steering wheel rim and a hub support configured to be non-rotatably coupled to a support structure of the vehicle. A stationary hub is coupled to the hub support, the steering wheel rim being rotatable relative to the stationary hub.

Abstract: A ball screw assembly includes a helical path for a plurality of balls to be routed through, the helical path extending from a first end to a second end. The ball screw assembly also includes a recirculation path extending from a first transition location to a second transition location. The recirculation path includes a first segment defined by a first arc portion of a first ellipse. The recirculation path also includes a second segment defined by a second arc portion of the first ellipse. The recirculation path further includes a third segment defined by an arc of a second ellipse, wherein the first ellipse and the second ellipse are disposed in a common plane.

Abstract: An assembly includes a steering shaft and a primary drive system eccentrically coupled to the steering shaft and configured to transfer a torque applied to the steering shaft to a vehicle steering system. The assembly also includes a secondary drive system coupled to the steering shaft and configured to transfer the torque applied to the steering shaft if the primary drive system is inactive and substantially unable to transfer the torque.

Abstract: A pulley assembly including a drive pulley, a driven pulley, a flexible belt configured to connect the drive pulley to the driven pulley, an idler including a bearing and an idler pulley, the idler pulley engaged with the belt, the idler rotating about a first longitudinal axis, and an axial trap within the pulley assembly configured to restrict longitudinal movement of the idler along the first longitudinal axis.

Abstract: A power assist system includes a motor having a rotor shaft, a drive pulley attached to the rotor shaft, a driven pulley, a flexible belt configured to connect the drive pulley to the driven pulley, and a ball screw assembly. The ball screw assembly includes a rotatable ball screw rotatable with the driven pulley, a linearly translated ball nut surrounding the ball screw, and an anti-rotation device arranged to prevent rotation of the ball nut.

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.

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.