Abstract: A steering column assembly for a vehicle, comprises a shroud comprising an axially movable upper portion and an axially fixed lower portion, which move telescopically to provide adjustment for reach of the steering column assembly, a steering shaft supported by the shroud, a pivot which connects a part of the lower portion to a fixed part of the vehicle, a clamp mechanism which releasably fixes the upper and lower portions and the shroud in position relative to a further fixed part of the vehicle. A sprung support assembly is secured to a fixed part of the vehicle and includes an axle that passes underneath the upper portion of the shroud and a cylindrical roller that surrounds a part of the axle and has an outer surface that engages the underside of the shroud and an inner surface that bears on the axle, the sprung support at least partially supports the weight of the shroud when the clamp mechanism is released, and the cylindrical roller rotating around the axle as the shroud is adjusted for reach.

Abstract: A collapsible steering column assembly for a vehicle comprises a shroud which surrounds a steering column shaft, a mounting bracket secured to or integral with a fixed part of the vehicle, a support bracket secured to the mounting bracket through one or more frangible connectors, a clamp mechanism which releasably secures the shroud to the support bracket, and a blocking part which is fixed in position relative to the mounting and at least in an unclamped condition of the clamp mechanism provides an additional force path between the clamp mechanism and the mounting bracket that does not pass through the support bracket. In the event that an axial load is applied to the steering assembly when the clamp mechanism is unlocked and has reached the end of its allowable travel at least some of the load is carried through the clamp mechanism and the blocking part to the mounting bracket along the additional force path.

Abstract: An adjustable steering column assembly includes a releasable clamp assembly that clamps a shroud of the assembly in position relative to a support bracket, the clamp assembly including an elongate clamp bolt onto which are stacked: at least a part of an adjustable shroud of the steering assembly, and a cam mechanism comprising a fixed cam part and a moving cam part, the two parts each having a bore through which the clamp bolt passes, a thrust bearing, and a locking nut which includes an internal thread that engages a complimentary thread on the clamp bolt and which is locked down so as to apply an axial load to the thrust bearing. The assembly also includes a tapered compliant bush which is pressed into a space defined between the clamp bolt and the bore of the moving cam part of the cam mechanism with the relatively thick end of the bush nearest the thrust bearing and with the thrust bearing applying an axial load to the bush.

Abstract: A steering column assembly comprises an adjustable shroud which at least partially surrounds a steering shaft and a clamp mechanism operable between a clamped position in which the adjustable shroud part is locked in position and an unclamped position in which the adjustable shroud part can be moved to set the reach and/or rake of the steering column assembly, in which the clamp mechanism comprises a clamp pin, a locking handle and a cam mechanism fitted to the clamp pin, in which the cam mechanism comprises first and second cam portions which can be moved relative to each other by operation of the locking handle to vary the overall length of the cam mechanism, the unclamped position of the cam mechanism being defined by contact of a first end stop of the first cam portion with a second end stop of the second cam portion.

Abstract: A gearbox assembly for all electric power steering apparatus comprises an input shaft which carries a worm gear and is supported relative to the housing at one end by a first bearing assembly and at the other by a second bearing assembly, an output shaft which carries a wheel gear which is fixed relative to a housing and which meshes with a worm gear on the input shaft, and a spring assembly which acts between the housing and the first bearing assembly, and the spring assembly applying a biasing force onto the second bearing in a first direction away from the neutral position so as to ensure that the worm and wheel are fully engaged.

Abstract: An electric power assisted steering system comprises a motor connected to a portion of a steering mechanism through a worm carried by a worm shaft and a wheel carried by an output shaft operatively coupled to the steering mechanism. The shaft is supported in at least one bearing which has some internal clearances and supports the worm shaft in such a manner that it is free to pivot through an angle in planes which include its own axis due to a degree of axial free play of the first bearing assembly. The bearing assembly comprises an inner race having a groove, an outer race having a groove, and a plurality of ball bearings located between the inner and outer races, and in which the outer race groove is not round when in its position of use such that the ball bearings permit a greater freedom of movement of the inner race relative to the outer race in a first radial direction than in a second radial direction that is orthogonal to the first direction.

Abstract: A gearbox assembly for an electric power assisted steering assembly comprises a gearbox housing (20), an output shaft (23), a wheel gear assembly (22) comprising a hub (21) which is fixed to the output shaft by a locating means so as to prevent relative rotational and axial movement between the hub and the output shaft and a gear wheel fixed to the hub, at least one support bearing assembly (25,26) which supports the output shaft relative to the gearbox housing (20), a worm gear which engages the wheel gear (22), and a coupling for transmission of torque from the output shaft to an intermediate shaft that is external to the gearbox housing. The coupling includes a fixing part (31) which is fixed to the output shaft (23) through the gear assembly and the support bearing assembly is provided on the opposite side of the gear assembly (22) to the coupling (31) such that the gear assembly (22) is overhung from the portion of the output shaft supported by the bearings (25,26).

Abstract: A gearbox assembly for all electric power steering apparatus comprises an input shaft which carries a worm gear and is supported relative to the housing at one end by a first bearing assembly and at the other by a second bearing assembly, an output shaft which carries a wheel gear which is fixed relative to a housing and which meshes with a worm gear on the input shaft, and a spring assembly which acts between the housing and the first bearing assembly, and the spring assembly applying a biasing force onto the second bearing in a first direction away from the neutral position so as to ensure that the worm and wheel are fully engaged.

Abstract: In a gearbox for use in an electric power assisted steering system comprises a housing, an input shaft located at least partially within the housing which carries a worm gear and includes means for coupling to a motor rotor at one end, an output shaft located at least partially within the housing which carries a wheel gear, and a first bearing means which supports the input shaft at a side of the worm distal from the end of the shaft which connects to the motor rotor and second bearing means which supports the input shaft at the other side of the worm, the invention comprises further providing a first biasing means adapted to apply an axial load to the input shaft to bias the axial clearance in the second bearing, the second biasing means acting upon a part of the first bearing means; and a second biasing means adapted to apply a radial load to the input shaft to bias the worm into engagement with the wheel gear, the second biasing means also acting upon a part of the first bearing means.

Abstract: A steering column assembly includes a steering column shroud comprising an inner member and an outer member, the inner member being at least partially received within the outer member, a support bracket which is fixed in position relative to a part of the vehicle, the outer member passing between two spaced apart arms of the bracket, and a clamp assembly which includes a cam mechanism movable between a locked position in which the clamp mechanism fixes the inner member and outer member in position relative to the support bracket and an unlocked position in which the clamp mechanism permits movement of at least one of the inner and outer members relative to the support bracket.

Abstract: An electric power assisted steering system comprises a motor connected to a portion of a steering mechanism through a worm carried by a worm shaft and a wheel carried by an output shaft operatively coupled to the steering mechanism. The shaft is supported in at least one bearing which has some internal clearances and supports the worm shaft in such a manner that it is free to pivot through an angle in planes which include its own axis due to a degree of axial free play of the first bearing assembly. The bearing assembly comprises an inner race having a groove, an outer race having a groove, and a plurality of ball bearings located between the inner and outer races, and in which the outer race groove is not round when in its position of use such that the ball bearings permit a greater freedom of movement of the inner race relative to the outer race in a first radial direction than in a second radial direction that is orthogonal to the first direction.

Abstract: In a gearbox for use in an electric power assisted steering system comprises a housing, an input shaft located at least partially within the housing which carries a worm gear and includes means for coupling to a motor rotor at one end, an output shaft located at least partially within the housing which carries a wheel gear, and a first bearing means which supports the input shaft at a side of the worm distal from the end of the shaft which connects to the motor rotor and second bearing means which supports the input shaft at the other side of the worm, the invention comprises further providing a first biasing means adapted to apply an axial load to the input shaft to bias the axial clearance in the second bearing, the second biasing means acting upon a part of the first bearing means; and a second biasing means adapted to apply a radial load to the input shaft to bias the worm into engagement with the wheel gear, the second biasing means also acting upon a part of the first bearing means.

Abstract: An assembly comprises a male component and a female component which connect together to form a mechanical connection, the female component being adapted to at least partially receive an end portion of the male component. The female component has at least one bore which is adapted to receive a clamping pin which can be tightened to clamp the female component around the male component. A guide is provided which is carried by the male component and which defines at least one blocking region and one opening region, the opening region being aligned with the at least one bore in the female component to permit insertion of the clamping pin into the bore when the male component and female component are correctly aligned and the blocking region otherwise preventing insertion of the clamping pin when the male component is inserted into the female component with an incorrect alignment. The guide assists in achieving correct alignment of the male and female components during assembly.

Abstract: An electrical power-assisted steering system is disclosed comprising a brushless electric motor (1) which has a plurality of phase windings connected at a start point and in which a switching means (13) such as a relay is provided in at least one phase of the motor, the switching means being movable between a closed position in which current is able to flow in the phase winding and an open position which prevents current flowing in the respective phase in the event of a fault. Also disclosed is a substantially rigid connector assembly (19) onto which is mounted the switching means (13), conductors (20) for connecting the motor phase windings and a motor position sensor (21) to an associated motor control means (6), the connector acting as a support for the motor stator, which simplifies the steps involved in assembly.

Abstract: An electrical power-assisted steering system comprising a brushless electric motor which has a plurality of phase windings connected at a star point and in which a switching device such as a relay is provided in at least one phase of the motor, the switching device being movable between a closed position in which current is able to flow in the phase winding and an open position which prevents current flowing in the respective phase in the event of a fault.

Abstract: An electric actuator for use in a vehicle power steering system includes an electric motor (20) and a gearbox (22). The electric motor (20) has a stator (26) and an armature (27) concentric with the stator (26) that is adapted to rotate about a common axis. A single common output shaft (40) extends through the actuator (14) to transmit torque from the motor (20) to a drive portion (70) of the output shaft (40) remote from the gearbox (22), from whence torque is transmitted to the gearbox (22) through a transmission portion (60) of the shaft (40). A clutch (21) may be provided between the motor (20) and the output shaft (40).