Patent ID: 7789191
Filing Date: 2010-09-07
Classification: B62D

Abstract:
1. An electric power assist module for a steering system, with the electric power assist module comprising: an integrated housing formed as a single piece; a torque sensor that is at least partially contained by the integrated housing; a motor that is at least partially contained by the integrated housing, wherein an electronic control unit that is at least partially contained by the integrated housing; a first electrical connection, wherein the first electrical connection extends from the torque sensor to the electronic control unit for providing signals from the torque sensor to the electronic control unit, and the first electrical connection is at least partially contained within the integrated housing; a second electrical connection, wherein the second electrical connection extends from the electronic control unit to the motor for providing power to the motor in response to the signals from the torque sensor, and the second electrical connection is at least partially contained within the integrated housing; an input shaft; an output shaft; a torsion bar having opposite first and second ends, wherein the first end of the torsion bar is connected to the input shaft so that the first end of the torsion bar rotates with the input shaft, and the second end of the torsion bar is connected to the output shaft so that the second end of the torsion bar rotates with the output shaft; a reduction gear assembly for transferring motion from the motor to the output shaft, wherein the reduction gear assembly comprises a helical gear train including a pinion gear, an intermediate gear and a steering gear; a lower housing that is mounted to the integrated housing, wherein the lower housing at least partially contains the helical gear train; and an upper cover mounted to the integrated housing, wherein the input shaft is rotatably mounted to the upper cover so that the input shaft is aligned with the output shaft, the motor extends through a first opening in the upper cover, a seal is provided between the motor and the upper cover for providing a substantially hermetic seal between the upper cover and the motor, and the input shaft extends through a second opening in the upper cover.