VARIABLE RATIO RACK AND PINION STEERING GEAR FOR VEHICLES

Abstract: In accordance with the present invention, there is provided a novel and improved variable ratio rack and pinion steering gear wherein the pinion (10) has teeth of variable shape and size and the rack (12) has teeth at least in part of variable shape and size. The teeth of the pinion are correctly meshable with a uniformly toothed rack profile (32) and adapted to provide variable pitch circles (10b). The teeth of the rack are adapted to be generated by using the profile of the pinion teeth in a manner to provide a desired variable ratio between the pinion and the rack.

Description: VARIABLE RATIO RACK AND PINION STEERING GEAR BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a variable ratio rack and pinion steering gear for road vehicles. 2. Description of the Prior Art A typical form of variable ratio rack and pinion steering gear is disclosed in the Japanese Patent Publication No. 52-29049 and wherein the pinion is formed to be a standard helical pinion having identical involute teeth whilst the rack is formed to be a variably contoured rack having teeth of variable shape and pitch. The rack teeth are adapted to be generated by using a cutter having blades of the same tooth form as that of the pinion, i.e., the rack teeth are adapted to be generated by using the profile of the pinion teeth. The rack and pinion steering gear of the abovedescribed type encounters a difficulty of obtaining an adequate strength in the rack, particularly when a relatively wide variation of gear ratio is required. This is due to the fact that the rack teeth have, at the region for providing a relatively small gear ratio, a tendency to be of great pressure angle and therefore to be sharp-edged at the tops and also have, at the region for a relatively small gear ratio, a tendency to have undercuts at the roots. In the case where this tendency is pronounced, a considerably wide variation in strength of the rack teeth and therefore a considerable reduction in steering force transfer efficiency will inevitably result. SUMMARY OF THE INVENTION In accordance with the present invention there is provided a novel and improved variable ratio rack and pinion steering gear. The pinion is of a circular form and has a concentric addendum circle. The teeth of the pinion are correctly. meshable with a uniformly toothed rack profile and adapted to provide such a variable pitch circle radius that is at a maximum at a predetermined position of the pinion, gradually reduces with the rotary movement of the pinion in eitner direction out of the predetermined position and is at a minimum at 1800 of rotary movement of the pinion out of the predetermined position. The rack in mesh with the pinion is generated by using the profile of the pinion teeth in a manner to provide a desired variable ratio between the pinion and the rack. With the rack and pinion constructed as above in accordance with the present invention, a wider variation of gear ratio can be attained without sacrificing the strength or rigidity of the steering gear, particularly of the rack teeth. It is an object of the present invention to provide a novel and improved variable ratio rack and pinion steering gear which is free from the foregoing drawbacks inherent in prior art rack and pinion steering gears of the described type. It is a further object of the present invention to provide a novel and improved variable ratio rack and pinion steering gear of the above-mentioned character which is enabled to have a wider variation of gear ratio without sacrificing the strength or rigidity of the steering gear, particularly the rack teeth. BI DESCRIPTION OF THE DRAWINGS The features and advantages of the variable ratio rack and pinion steering gear according to the present invention will become more clearly appreciated from the following description taken in conjunction with the accompanying drawings, in which: : Fig. 1 shows a variable ratio rack and pinion steering gear embodying the present invention; Fig. 2 shows a pinion constructed in accordance with the present invention and a uniformly toothed rack profile; Fig. 3 shows variable ratio rack and pinion constructed in accordance with the present invention; Figs. 4(A), h(B) and 4(C) show three operative conditions of the rack and pinion of Fig. 3 and show three rack sections corresponding to sections (B), (C) and (D) of Fig. 3, respectively; Figs. 5 and 6 show modifications of the present invention; Figs. 7 to 9 show three variable ratio characteristics of rack and pinion steering gears constructed in accordance with the present invention; Fig. 10 shows another form of a pinion constructed in accordance with the present invention; ; Fig. 11(A) shows a further embodiment of the present invention wherein the pinion of Fig. 10 is used; Fig 11(B) is a view similar to Fig. 11(A) but shows a further embodiment of the present invention; Figs. 12 and 13 show further forms of variable ratio characteristics of rack and pinion steering gear constructed in accordance with the present invention; and Fig. 14 shows the variation of a performance efficiency of a steering linkage with respect to a steering angle. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring first to Fig. 1, a variable ratio rack and pinion steering gear for an automotive vehicle is shown to comprise a pinion 10 and a rack 12. The pinion 10 is rotatably supported in a gear casing 14 through bearings 16 and 18. The rack 12 is in mesh with the pinion 10 and axially movable in the gear casing 14 in accordance with the rotary movement of the pinion 10. A pinion shaft 20 is provided with serrations 20a and adapted to be connected to, though not shown, a steering shaft which is, in turn, connected to a steering wheel. A sealing member 22 is arranged to provide a seal between the pinion shaft 20 and the gear casing 14. The rack 12 has its opposite ends projecting from the gear casing 14 and adapted to be connected at the opposite ends to steerable road wheels of the vehicle. A spring 24 is arranged to urge the rack 12 against the pinion 10 by way of a retainer 26, and its intensity is adjustable by advancing or retreating an adjusting nut 28. The nut 28 is locked at a set position by means of a lock nut after the adjustment of the intensity of the spring 24. The above structure substantially follows the conventional fashion. To produce a desired variable ratio relationship the pinion 10 and the rack 12 are constructed and arranged in accordance with the present invention as will be described hereinbelow. Fig. 2 shows the tooth profile of the pinion 10 constructed in accordance with the present invention. The pinion 10 is a circular gear having an addendum circle 10a concentric with the center 0 of rotation of the pinion. The teeth of the pinion 10 are of variable shape and size and correctly meshable with a uniformly toothed rack profile 32. The rack tooth profile 32 is uniform in shape and size and preferably a standard rack tooth profile as illustrated. The pinion 10 is adapted to provide varying pitch circles and more specifically adapted to provide an effective pitch circle radius rp which is at a maximum at a central or datum position of the pinion or when the operating angle of f pinion is zero, reduces gradually with the rotary movement of the pinion in either direction out of the datum position and is at a minimum when the operating angle of the pinion out of the datum position is 1800. The datum position of the pinion 10 is aligned with the straight-ahead position of the steering wheel. The pinion 10 is therefore given an intermeshing pitch line or curve 10b which is symmetrical about the axis A-A aligned with the datum position of the pinion. More specifically, the pinion 10 is shown to comprise six teeth including diametrically opposed first and second teeth 10c and 10d. The first pinion tooth 10c is symmetrical about the axis A-A and adapted to provide a maximum pitch circle radius at the middle point thereof, whilst the second pinion tooth lOd is also symmetrical about the axis A-A and adapted to provide a minimum pitch circle radius at the middle point thereof. The remaining two pairs of teeth 10e and 10f on the respective sides of the axis A-A of symmetry are adapted to provide a gradually reducing pitch circle radius as the pinion rotates progressively in either direction out of the datum position thereof. Each of the pinion teeth 10e and 10f does not have a symmetrical profile. The pinion 10 is generated by using a hob or cutter having blades of the same tooth form as the uniformly toothed rack profile 32 which is preferably a standard rack tooth profile as shown in Fig. 2. In the variable ratio rack and pinion steering gear of according to one embodiment of the present invention, the pinion 10 constructed in the above manner is used, and the gear ratio is adapted to vary as the position of meshing engagement of the pinion 10 and the rack 12 changes with the rotary movement of the steering wheel. However, when the teeth of the rack 12 are constructed to be of uniform shape and size as, for example, of the standard rack tooth profile 32, the resulting variable ratio characteristics of the rack and pinion steering gear will become such one as represented by a dotted line "a' in the graph of Fig. 7. That is, the resulting ratio characteristics are represented by the undulating or waved line "a" in the graph of Fig. 7 which undulates in cycles in the way of completing one cycle per one revolution of the pinion 10 in response to the rotation g of the steering wheel. The variable ratio characteristics of rack and pinion steering gear normally considered desirable are, however, such one as represented by a solid line bn in the graph of Fig. 7. That is, when the steering angle g is smaller than 180 , a relatively small gear ratic is desired for the purpose of obtaining a highspeed stability, whereas when the steering angle g is larger than 1800, a relatively large gear ratio is desired for the purpose of obtaining a light and smooth feel in steering operation under low-speed turning or standstill conditions. To achieve such desired variable ratio characteristics the rack 12 used in the rack and pinion steering gear of the present invention is constructed to have such a tooth profile as shown in Fig. 3. That is, the rack 12 is generated by using the profile of the pinion 10 teeth in a manner to provide such a non-uniformity of relative movement of the pinion 10 and the rack 12 that enables to provide the desired variable ratio characteristics represented by the line "b" in the graph of Fig. 7. The rack 12 produced in the above manner is given an intermeshing pitch line 12a when arranged to cooperate with the pinion 10 having the intermeshing pitch line 10b. With the rack 12 and the pinion 10 constructed in the above manner according to the present invention, the desired variable ratio characteristics represented by the line t'b" in the graph of Fig. 7 can be obtained. In the foregoing rack and pinion steering gear of the present invention, the teeth of the pinion 10 constructed in the above described manner have, at the region including the pinion tooth 10c, relatively small pressure angles and also have, at the region including the pinion tooth 10d, relatively large pressure angles. Due to this, the teeth of the rack 12 generated by using the profile of the pinion 10 teeth have, at the region near the midpoint corresponding to the steering angle of zero, plus-shifted tooth profiles as shown in Fig. 4(A) and have, at the region corresponding to the steering angle of about 1800, tooth profiles similar to the standard rack tooth profile 32 as shown in Fig. 4(B) and further have, at the region corresponding to the steering angle of about 3600, minus-shifted tooth profiles as shown in Fig. 4(C). This, however, does not cause the teeth of the rack 12 to have any pointed tops at the region for a relatively small gear ratio or any undercuts in the roots at the region for a relatively large gear ratio but allows the rack teeth to have a tooth profile similar to the standard rack tooth profile 32. With the rack 12 and the pinion 10 constructed in the above manner, a wider variation of gear ratio is possible without sacrificing the strength or rigidity of the steering gear, particularly of the rack teeth. Fig. 5 shows another embodiment of the present inio. In this embodiment, while the teeth of the rack 12 at the region corresponding to the steering angle of 0 to 180 are constructed in the same manner as the previous embodiment of Fig. 3, the teeth of the rack 12 at the region corresponding to the steering angle of more than 1800 are constructed to have a standard rack tooth profile as the profile 32. With the above structure, the ratio characteristics represented by a solid line "c" in the graph of Fig. 8 results and wherein while the portion of the line "c" corresponding to the steering angle of more than 1800 is adapted to conform to the desired characteristics line nub", the portion of the line c corresponding to the steering angle of more than 1800 is not adapted to conform to the line "b" but to the line "a", thus slightly deviates from the desired ratio characteristics. However, since such deviation occurs at the region for a relatively high gear ratio and further since the amount of deviation is relatively small, no substantial problems occur in practical use but a considerable reduction in steering effort can be obtained. In the embodiment of Fig. 5, since the profile of the rack 12 teeth differs only at the region near the midpoint from the standard rack tooth profile 32 but is, at the remaining regions, a standard rack tooth profile itself, this embodiment of Fig. 5 enables to realize the solution of the foregoing problems in the prior art more completely and assuredly than the previous embodiment of Fig. 3. Furthermore, the rack 12 in this embodiment can be produced more easily and therefore is inexpensive in manufacturing cost. In either of the previous embodiments of Figs. 3 and 5, the pinion 10 is preferably constructed to be a helical pinion as shown in Fig. 6, whilst the rack 12 is constructed to have correspondingly oblique teeth, whereby the number of teeth of the rack and pinion brought into meshing engagement at the same time is increased, thus enabling smooth mesh even when the rack and pinion constructed to provide a considerably wide variation of gear ratio. The ratio characteristics of variable ratio rack and pinion steering gear of the present invention are not limited to the foregoing b and "c" but may be arbitrarily chosen. For example, the ratio characteristics may be such one as represented by a line "d" in the graph of Fig. 9 that are particularly suited for use in power-2ssisted steering systems and adapted to effect, in a manner completely reverse to the foregoing characteristics "b" and "c", a relatively large gear ratio when the steering angle Q is smaller than 1800 and a relatively small gear ratio when the steering angle g is larger than 1800. In this case, the same effects as the previous embodiments of Figs. 3 and 5 can be attained by constructing so that the pitch circle radius of the pinion is at a minimum when the operation angle of the pin on is zero and at a maximum when the operating angle of the pinion is 1800. Fig. 10 shows another form of the pinion 10 with five teeth. The pinion 10 is constructed in the manner similar to the previous form and has a concentric addendum circle 10a and a symmetrical intermeshing pitch line or curve lUb. The pitch circle radius rp of the pinion 10 is variable with the angular movement of the pinion in the manner similar to the previous form. Fig. 11(A) shows a further embodiment of the present invention. In this embodiment, the pinion 10 shaped into the form of Fig. 10 is used. The rack 12 is generated by using the profile of the pinion 10 teeth in a manner to achieve the variable ratio characteristics represented by the line "b" in the graph of Fig. 7 or Fig. 12. This embodiment can produce substantially the same effect as the previous embodiment of Fig. 3. Fig. 11(B) is a view similar to Fig. 11(A) but shows a further embodiment of the present invention. In this embodiment, while the pinion 10 shaped into the form of Fig. 10 is used as in the previous embodiment of Fig. 11(A), the rack 12 is generated by using the profile of the pinion 10 teeth in a manner to achieve such variable ratio characteristics as represented by the line "e" in the graph of Fig. 12. That is, in or adjacent the central position of the steering wheel the gear ratio is at a minimum and held constant, as indicated by the line section e As the steering wheel is turned in either direction away from the central position or as the steering angle g increases, the gear ratio increases sharply or rapidly for a given rotary movement of the steering wheel, as indicated by the line section e2, after having been held constant along the line section e 1. As the steering wheel is turned further or as the steering angle g increases beyond about 1800, the gear ratio comes to increase gradually or slowly for a given rotary movement of the steering wheel, as indicated by the line section e3. The characteristics line tten is thus adapted to conform at the line sections el and e2 to the characteristics line "b" but not at the line section e3. The line section e3 deviates maximumly from the characteristics line "b" when the steering angle g is about 1800 and goes nearer thereto as the steering angle 8 becomes larger. The rack 12 in the embodiment of Fig. 11(B) can attain an improved strength for a given size more assuredly and efficiently than the previous embodiment of Fig. 11(A), as will be understood from the graph of Fig. 12. Namely, the profile of the rack teeth generated to obtain the characteristics line "b" deviates from the standard rack tooth profile in substantially proportional relationship to the deviation of the characteristics line "b" from the characteristics line "a" in the graph of Fig. 12, whilst the profile of the rack teeth generated to obtain the characteristics line "e" deviates from the standard rack tooth profile in substantially proportional relationship to the deviation of the characteristics line "e" from the characteristics line "a" in the graph of Fig. 12. In this connection, the racks 12 of the embodiments of Figs. 11(A) and 11(B) have at the region corresponding to the steering angle of zero a common deviation-of 1 E a and also have at the region corresponding to the steering angle of 3600 (similarly at 7200) deviations A 2 and a E 3, respectively. Since the deviations AE 3 is smaller than A E 2 the profile of the rack 12 teeth of the embodiment of Fig. 11(B) is, as a whole, more similar to the standard rack tooth profile. Furthermore, since the deviation AE 1 is not so large, it does not cause any pointed or sharp-edged tops. Thus, in the embodiment of Fig. 11(B), the gear ratio is adapted to increase gradually even when the steering angle g is relatively large. This ratio characteristics "e" is optimally combined with the performance characteristics of a steering linkage to enable to maintain the steering effort substantially constant throughout the steering operation from lock to lock. That is, as shown in Fig. 14, the performance efficiency of the typical steering linkage comprising side rod assemblies, knuckle arms and so on, is at a maximum when the steering angle is about 1800 and then reduces gradually as the steering angle g increases. In Fig. 13, a ratio characteristics line "f" is shown which is particularly suited for use in powerassisted steering system and adapted to effect, in the manner completely reverse to the ratio characteristics "e", such a variable ratio that is at a maximum and kept substantially constant when the steering wheel is at or adjacent the central position (corresponding to the steering angle ranging from - O1 to Q), reduces sharply or rapidly for a given rotary movement of the steering wheel when the steering angle varies from to to Q2 or -g1 to -g2 and reduces gradually or slowly for a given rotary movement of the steering wheel when the steering angle varies beyond O2 or - 82. In this case. the same effects as the embodiment of Fig. 11(B) can be attuned by constructing and arranging so that the pitch circle of the pinion 10 is at a minimum when the operating angle of the pinion is zero and at a maximum when the operating angle of the pinion is 1800 With the ratio characteristics "e", the variation of gear ratio occurs rectlinearly or along a straight line. Alternative to the ratio characteristics "e", such ratio characteristics may be used that is shown by a curve "g" in Fig. 13. With this characteristics curve flgfl, the gear ratio varies smoothly along the curve. In this case, when a variation of steering angle occurs within the range from -g1 to @1 the gear ratio varies along a curve calculated by the following equation: E =&alpha; = +6 where a,/ s & re constants When the steering angle is larger than O, the gear ratio varies along a curve calculated by the following equation: E = r (8+ p ) a where r, p, a are constants The ratio characteristics curve "g" enables a smooth variation of gear ratio and therefore a smooth and light feel in steering operation. Obviously, many variations and modifications of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

Claims: WHAT IS CLAIMED IS: 1. A variable ratio rack pinion steering gear comprising: a circular driving pinion (10) having a concentric addendum circle (10a), the teeth of the pinion being correctly meshable with a uniformly toothed rack profile (32) and adapted to provide such a variable pitch circle radius (rp) that is at a maximum at a predetermined position of the pinion, reduces gradually with the rotary movement of the pinion in either direction out of said predetermined position and is at a minimum at 1800 of rotary movement of the pinion out of said predetermined position; and a driven rack (12) in mesh with said pinion, the teeth of the rack being generated by using the profile of said pinion teeth in a manner to provide a desired variable ratio between the pinion and the rack. 2. Q variable ratio rack and pinion steering gear as set forth in Claim 1, wherein said pinion (10) comprises an intermeshing pitch curve (10b) symmetrical about an axis of symmetry (A-A), said axis of symmetry being aligned with said predetermined position of the pinion. 3. A variable ratio rack and pinion steering gear as set forth in Claim 1, wherein said uniformly toothed rack profile (32) comprises a standard rack tooth profile. 4. A variable ratio rack and pinion steering gear as set forth in Claim 1, wherein said rack (12) comprises a first group of teeth of variable shape and size and a second group of teeth of uniform shape and size. 5. A variable ratio rack and pinion steering gear as set forth in Claim 4, wherein said first first group of rack teeth are adapted to be meshable with said pinior when the operating angle of the pinion out of said predetermined position is smaller than 1800, and said second. group of rack teeth are adapted to be meshable with sad pinion when the operating angle of said pinion out of said predetermined position is larger than 1800 6. A variable ratio rack and pinion steering gear as set forth in Claim 5, wherein said second group of rack teeth have a standard rack tooth profile. 7. A variable ratio rack and pinion steering gear as set forth in Claim 1, wherein said pinion (10) comprises a helical pinion. 8. A variable rato rack and pinion steering gear as set forth in Claim 1, wherein said rack (12) is generated in a manner to provide a substantially constant gear ratio when the pinion (10) is at or adjacent said predetermined position, a widely varying gear ratio for a given rotary movement of the pinion when the operating angle of the pinion is relatively small, and a gradually varying gear ratio for a given rotary movement of the pinion when the operating angle of the pinion is relatively large. 9. A variable ratio rack and pinion steering gear as set forth in Claim 1, wherein said rack (12) is generated in a manner to provide a substantially constant minimum gear ratio when the pinion (10) is at or adjacent said predetermined position, a rapidly increasing gear ratio for a given rotary movement of the pinion out of said predetermined position when the operating angle of the pinion is relatively small, and a gradually increasing gear ratio for a given rotary movement of the pinion out of said predetermined position when the operating angle of the pinion is relatively large. 10. A variable ratio rack and pinion steering gear as set forth in Claim 1, wherein said rack (12) is generated in a manner to provide a substantially constant maximum gear ratio when the pinion (10) is at or adjacent said predetermined position, a rapidly decreasing gear ratio for a given rotary movement of the pinion out of said predetermined position when the operating angle of the pinion is relatively small, and a gradually decreasing gear ratio for a given rotary movement of the pinion out of said predetermined position when the operating angle of the pinion is relatively large. 11. A variable ratio rack and pinion steering gear as set forth in Claim 8, 9 or 10, wherein said gear ratio is variable in a curved manner with the variation of the steering angle.

Inventors: HIGUCHI, MEGUMU, YANAI, TOKIYOSHI
Applicants: NISSAN MOTOR CO., LTD.
Application year: 1981
Main classification: B62D3
IPC codes: F16H55, B62D3