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: 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 system having a pinion and an input shaft is disclosed. The pinion includes an outer surface and at least one pinion stop tooth located along the outer surface. The at least one pinion stop tooth has a pair of pinion pressure surfaces. The input shaft defines a recess configured for receiving the pinion. The input shaft includes an inner surface located within the recess and at least one shaft stop tooth located along the inner surface. The at least one shaft stop tooth has a pair of shaft pressure surfaces. A specific shaft pressure surface is positioned to generally oppose a specific pinion pressure surface, and the specific shaft pressure surface and the specific pinion pressure surface are generally parallel to one another.

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 vehicle electric power steering (EPS) control system includes a motor operatively coupled to an EPS linkage arrangement, the motor comprising a first winding and a second winding. Also included is a power source for the motor. Further included is a controller in operative communication with the motor and the power source. The controller includes a microprocessor configured to receive input from a torque sensor and a motor sensor. The EPS controller also includes a first field-effect transistor (FET) driver in operative communication with the microprocessor and a first plurality of FETs operatively connected to the first winding of the motor. The EPS controller further includes a second FET driver in operative communication with the microprocessor and a second plurality of FETs operatively connected to the second winding of the motor.

Abstract: A gear mechanism usable in an electric power steering system is provided. The gear mechanism includes a gear housing including a passage formed therein, a gear positioned in the passage, and a signal transmission medium positioned in the passage adjacent the gear. A partition is inserted into the passage to prevent contact between the signal transmission medium and the gear.

Abstract: A ball screw mechanism including a screw having a first axis and at least one screw groove extending along a first helical path about the first axis, and a nut having a first aperture receiving the screw. The nut also includes at least one nut groove extending along a second helical path about the first axis between first and second edges disposed on opposite sides of the screw. The at least one screw groove and the at least one nut groove are aligned and cooperate to form a helical passageway extending at least 180 degrees about the first axis between a first opening at the first edge and a second opening at the second edge. The ball screw mechanism also includes a plurality of balls moving, in part, along the helical passageway.

Abstract: A vehicle power steering assembly is provided. The vehicle power steering assembly includes an input shaft having first and second end portions that extend along an axis, and a first aperture that extends substantially axially into the first end portion. The vehicle power steering assembly further includes a torsion shaft having third and fourth end portions. The third end portion has a first plurality of splines and the fourth end portion has a second plurality of splines. The third end portion is disposed in the first aperture of the input shaft. The first plurality of splines on the third end portion fixedly couples the torsion shaft to the input shaft. The vehicle power steering assembly further includes an output shaft having fifth and sixth end portions, and a second aperture that extends substantially axially into the fifth end portion toward the sixth end portion. The fourth end portion of the torsion shaft is disposed in the second aperture of the output shaft.

Abstract: A gear mechanism usable in an electric power steering system is provided. The gear mechanism includes a gear housing including a passage formed therein, a gear positioned in the passage, and a signal transmission medium positioned in the passage adjacent the gear. A partition is inserted into the passage to prevent contact between the signal transmission medium and the gear.

Abstract: A belt tensioner apparatus is provided for a pulley assembly having an input pulley rotatably connected to an output pulley via a flexible belt. The tensioner apparatus includes a belt contact device engaged with a first portion of the belt and also engaged with a second portion of the belt different from the first portion of the belt. The belt contact device is coupled to a base so as to enable movement of the belt contact device with respect to the base, such that the belt contact device moves against the second portion of the belt responsive to a tension force created in the first portion of the belt by rotation of the input pulley, to create a tension force in the second portion of the belt.

Abstract: An electric power steering system for a vehicle including a shaft assembly, a torque sensor assembly in operable communication with the shaft assembly, and a housing disposed around the torque sensor assembly. The shaft assembly includes a first shaft element, a second shaft element, and a torsion bar coupling the second shaft element to the first shaft element. At least one bearing is positioned between the first shaft element and the second shaft element for supporting a portion of the first shaft element within the housing. The housing includes a first housing portion and a second housing portion secured to the first housing portion by an interference fit formed between the first and second housing portions.

Abstract: An apparatus for measuring relative displacement between a first shaft and a second shaft includes first and second rotor assemblies. The first rotor assembly is coupled to the first shaft and is centered on an axis. The second rotor assembly is coupled to the second shaft. The second rotor assembly has first and second stator plates. Each of the first and second stator plates includes an upper surface and a lower surface. The upper and lower surfaces are parallel. The first and second stator plates include a plurality of teeth extending in a direction radial of the axis. The first and second stator plates form a gap between the lower surface of the first stator plate and the upper surface of the second stator plate. The apparatus further includes at least one magnet having a magnetic field and disposed on the first rotor assembly and a sensing device disposed within the gap for sensing a magnetic flux of the magnetic field.

Abstract: An apparatus for measuring relative displacement between a first shaft and a second shaft includes first and second rotor assemblies. The first rotor assembly is coupled to the first shaft and is centered on an axis. The second rotor assembly is coupled to the second shaft. The second rotor assembly has first and second stator plates. Each of the first and second stator plates includes an upper surface and a lower surface. The upper and lower surfaces are parallel. The first and second stator plates include a plurality of teeth extending in a direction radial of the axis. The first and second stator plates form a gap between the lower surface of the first stator plate and the upper surface of the second stator plate. The apparatus further includes at least one magnet having a magnetic field and disposed on the first rotor assembly and a sensing device disposed within the gap for sensing a magnetic flux of the magnetic field.

Abstract: A single planet planetary differential including a shaft mechanism, a planet gear, disposed so as to be meshingly communicated with the shaft mechanism, a carrier device, the carrier device defining a carrier cavity for rotatingly containing the planet gear, a worm gear, wherein the worm gear is disposed so as to be meshingly communicated with the carrier device and a differential housing, wherein the differential housing defines a differential cavity for rotatingly containing the shaft mechanism and the carrier device and wherein the differential housing defines a worm gear cavity for rotatingly containing the worm gear.

Abstract: A rack-and-pinion steering gear is provided. The gear comprises a lower shaft, a pinion gear, a first bearing, and a plurality of stakes. The lower shaft has a first end, a second end, and a shoulder depending radially outward from the lower shaft. The pinion gear is defined in a portion of the lower shaft proximate the first end. The first bearing has a first side, a second side, and an inner edge. The inner edge is disposed on the lower shaft such that the first side abuts the shoulder. The stakes have a first section that conforms to a radius defined at an intersection of the second side and the inner edge of the first bearing, and a second section resting against the second side of the first bearing.

Abstract: An apparatus for measuring relative displacement between a first shaft and a second shaft includes first and second rotor assemblies. The first rotor assembly is coupled to the first shaft and is centered on an axis. The second rotor assembly is coupled to the second shaft. The second rotor assembly has first and second stator plates. Each of the first and second stator plates includes an upper surface and a lower surface. The upper and lower surfaces are parallel. The first and second stator plates include a plurality of teeth extending in a direction radial of the axis. The first and second stator plates form a gap between the lower surface of the first stator plate and the upper surface of the second stator plate. The apparatus further includes at least one magnet having a magnetic field and disposed on the first rotor assembly and a sensing device disposed within the gap for sensing a magnetic flux of the magnetic field.

Abstract: A ball-screw assembly comprising a ball-nut, a ball screw, a shell assembly, and an isolator member. The ball-nut threadingly engages the ball screw such that rotation of the ball-nut causes the rack shaft to move in a linear direction or vice versa. The shell assembly defines a cavity having the ball-nut disposed therein. The isolator member is disposed between the shell assembly and the ball-nut and transmits rotational forces between the shell assembly and the ball-nut. The isolator member acts as a spherical joint to allow the ball-nut and the ball screw to pivot within the shell assembly about a point on an axis of the ball screw, without causing the shell assembly to move.

Abstract: A ball screw assembly includes a ball nut or a ball screw having internal or external, respectively, helical curves, wherein two adjacent turns of the helical curves are joined by a crossover/crossunder path, wherein ends of the crossover/crossunder path and ends of the helical curves are integrally joined without interruption. A ball screw assembly may further include crossover/crossunder paths which are staggered about the screw or the nut.

Abstract: A single planet planetary differential including a shaft mechanism, a planet gear, disposed so as to be meshingly communicated with the shaft mechanism, a carrier device, the carrier device defining a carrier cavity for rotatingly containing the planet gear, a worm gear, wherein the worm gear is disposed so as to be meshingly communicated with the carrier device and a differential housing, wherein the differential housing defines a differential cavity for rotatingly containing the shaft mechanism and the carrier device and wherein the differential housing defines a worm gear cavity for rotatingly containing the worm gear.

Abstract: A rack-and-pinion steering gear is provided. The gear comprises a lower shaft, a pinion gear, a first bearing, and a plurality of stakes. The lower shaft has a first end, a second end, and a shoulder depending radially outward from the lower shaft. The pinion gear is defined in a portion of the lower shaft proximate the first end. The first bearing has a first side, a second side, and an inner edge. The inner edge is disposed on the lower shaft such that the first side abuts the shoulder. The stakes have a first section that conforms to a radius defined at an intersection of the second side and the inner edge of the first bearing, and a second section resting against the second side of the first bearing.