US20050087384A1 - Steer-by-wire handwheel actuator - Google Patents
Steer-by-wire handwheel actuator Download PDFInfo
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- US20050087384A1 US20050087384A1 US10/988,472 US98847204A US2005087384A1 US 20050087384 A1 US20050087384 A1 US 20050087384A1 US 98847204 A US98847204 A US 98847204A US 2005087384 A1 US2005087384 A1 US 2005087384A1
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- 239000003638 chemical reducing agent Substances 0.000 claims description 9
- 239000012530 fluid Substances 0.000 description 10
- 230000005540 biological transmission Effects 0.000 description 4
- 239000006249 magnetic particle Substances 0.000 description 4
- 230000008859 change Effects 0.000 description 3
- 230000036316 preload Effects 0.000 description 3
- 230000000295 complement effect Effects 0.000 description 2
- 230000000717 retained effect Effects 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D5/00—Power-assisted or power-driven steering
- B62D5/001—Mechanical components or aspects of steer-by-wire systems, not otherwise provided for in this maingroup
- B62D5/005—Mechanical components or aspects of steer-by-wire systems, not otherwise provided for in this maingroup means for generating torque on steering wheel or input member, e.g. feedback
- B62D5/006—Mechanical components or aspects of steer-by-wire systems, not otherwise provided for in this maingroup means for generating torque on steering wheel or input member, e.g. feedback power actuated
Definitions
- This invention relates to a steer-by-wire system, and more particularly to a steer-by-wire handwheel actuator.
- a steer-by-wire system has no mechanical link connecting the steering wheel from the road wheels.
- the steering wheel is little more than a joystick, albeit an extremely sophisticated joystick.
- Exemplary of such known steer-by-wire systems is commonly-assigned U.S. Pat. No. 6,176,341, issued Jan. 23, 2001 to Ansari, which is wholly incorporated herein by reference. What is needed is to provide the steer-by-wire driver with the same “road feel” that a driver receives with a direct mechanical link.
- a device that provides positive on-center feel and accurate torque variation as the handwheel is rotated is also desirable.
- Existing steer-by-wire devices produce excessive lash, excessive noise and insufficient over-load torque capability as the handwheel is rotated to its end of travel in either direction.
- a steer-by-wire steering system is defined as a steering system with no mechanical connection between a steering wheel and a set of steering gears or actuators. Such systems are advantageous because they permit auto and other vehicle designers great latitude in use of space that would normally be taken up by mechanical linkages, among other reasons.
- a steer-by-wire handwheel actuator which provides feedback of road forces to the operator of a steer-by-wire vehicle.
- a handwheel actuator comprises a driver input shaft; a gear train connected to the driver input shaft; a motor responsive to control signals from a controller and connected to the gear train; an electro-mechanical brake responsive to the control signals from the controller and connected to one of the driver input shaft and the gear train; and a stop mechanism attached to a housing and coupled to one of the electro-mechanical brake and the gear train.
- FIG. 1 is a perspective view of a prior art hard contact driving system
- FIG. 2 is a schematic representation of the steer-by-wire handwheel actuator in signal communication with a steer-by-wire steering system
- FIG. 3 is a perspective view of an exemplary embodiment of a steer-by-wire handwheel actuator
- FIG. 4 is a rear/plan view of a an exemplary embodiment of a steer-by-wire handwheel actuator of FIG. 3 ;
- FIG. 5 is a front /plan view of a an exemplary embodiment of a steer-by-wire handwheel actuator shown in FIG. 4 detailing cross sectional divisions that follow;
- FIG. 6 is a cross section view of an exemplary embodiment of a steer-by-wire handwheel actuator depicted in FIG. 5 , Section 6 - 6 ;
- FIG. 7 is a cross section view of an exemplary embodiment of a steer-by-wire handwheel actuator depicted in FIG. 5 , Section 7 - 7 ;
- FIG. 8 is a cross section view of an exemplary embodiment of a steer-by-wire handwheel actuator depicted in FIG. 5 , Section 8 - 8 ;
- FIG. 9 is a cross section view of a modular unit attached to a steering shaft to provide auxiliary steering resistance
- FIG. 10 is a cross section view of an alternative embodiment of the steer-by-wire handwheel actuator of FIG. 3 with a combination worm gear and direct drive power transmission;
- FIG. 11 is another cross section view of the alternative embodiment of the steer-by-wire handwheel actuator of FIG. 10 with worm gear power transmission taken perpendicular to the view of FIG. 10 .
- FIG. 1 a typical prior art steering system is depicted.
- a steering wheel 10 is connected to a steering column 11 which in turn is connected to a steering intermediate shaft 12 via universal joint 14 .
- Another universal joint 16 couples intermediate steering shaft 12 to an electric power steering assist assembly (rack assist) 18 . It is evident that mechanical direct connection exists throughout the prior art driving system.
- rack assist electric power steering assist assembly
- FIG. 2 is a schematic representation of a steer-by-wire steering system 600 as it is comprises a controller 400 , a first electro-mechanical actuator 202 and a second electro-mechanical actuator 302 , each actuator 202 , 302 in signal communication 400 a , 400 b with the controller 400 .
- the first and second electro-mechanical actuators 202 , 302 comprising a motor, crank arm, steering arm and tie rod, are in turn connected respectively to a first wheel 200 and a second wheel 300 and are operative thereby to steer the wheels 200 , 300 under the command of the controller 400 .
- one actuator is optionally linked to both road wheels 200 , 300 to operably steer wheels 200 , 300 using one motor to actuate the sole actuator.
- a handwheel actuator 100 of the present disclosure is in signal communication 100 a , 100 b with the controller 400 of the steer-by-wire steering system 600 .
- Handwheel actuator 100 is in further communication with an external motive source 500 , such as a driver from whom the handwheel actuator 100 receives steering commands by way of a driver input shaft 102 .
- the controller 400 is also operative to receive as input thereto a signal 700 indicative of vehicle velocity, as well as a signal 500 a indicative of the position of the driver input shaft 102 and a signal 500 b indicative of the torque on the driver input shaft 102 .
- Signals 500 a and 500 b are generated from sensors disposed in handwheel actuator 100 proximate shaft 102 .
- the handwheel actuator 100 includes a housing 130 , a driver input shaft 102 and a gear train 104 coupled to the driver input shaft 102 .
- the gear train 104 comprises a driver feedback pulley 106 , a speed reducer pulley 108 , and a spur gear 110 (See also FIG. 7 , as gear train 104 is shaded completely).
- the driver input shaft 102 is rotatably positioned between an upper bearing 54 and a lower bearing 56 , and position sensors 20 and torque sensor 22 operably connected to driver input shaft 102 .
- Position sensors 20 electronically detect the angular position of the driver input shaft 102
- the torque sensor 22 electronically detects and evaluates the torsional force acting on the driver input shaft 102
- the angular displacement of the hand steering wheel 10 is detected by sensors 20 , 22 , processed, and applied to a servo motor (not shown) to move steerable wheels (not shown).
- the handwheel actuator 100 of FIGS. 3 and 6 includes an electric motor 114 having a motor shaft 116 rotatively driven by the motor 114 . Attached or optionally formed into the motor shaft 116 is a motor pulley 118 . Attached to the motor pulley 118 is a belt 128 positively driving pulley 108 of the gear train 104 . Continuing in FIG.
- the handwheel actuator 100 further includes an electro-mechanical brake 120 having an electro-mechanical brake shaft 122 rotatively controlled by the electro-mechanical brake 120 .
- Attached or optionally formed into the electro-mechanical brake shaft 122 is a pulley 124 driving a belt 136 operably connected to the gear train 104 . More specifically, the belt 136 is connected to the driver feedback pulley 106 in an exemplary embodiment.
- a preferred embodiment of the handwheel actuator utilizes an electric sine commutated brushless motor 114 for its primary power transmission because the sine wave commutation provides for a low torque ripple.
- the belt 128 used to transmit the power from the motor 114 is a small-cogged belt to provide positive drive, high efficiency, low noise, and nearly zero lash. In using a cogged belt, it has been found to yield approximately 98% efficiency.
- a preferred embodiment uses a magnetic particle brake for the electro-mechanical brake 120 , however alternative embodiments also include electro-rheological fluid devices.
- Magnetorheological fluids suitable for use in the handwheel actuator 100 are disclosed in U.S. Pat. No. 5,896,965, issued 27 Apr. 1999, to Gopalswamy et al. for a Magnetorheological Fluid Fan Clutch; U.S. Pat. No. 5,848,678, issued 15 Dec. 1998, to Johnston et al. for a Passive Magnetorheological Clutch; U.S. Pat. No. 5,845,752, issued 8 Dec. 1998, to Gopalswamy et al. for a Magnetorheological Fluid Clutch with Minimized Resistance; U.S. Pat. No. 5,823,309, issued 20 Oct. 1998, to Gopalswamy et al.
- utilizing a magnetic particle brake or a magnetorheological fluid device provides virtually no resistance to a driver input shaft when there is no magnetic force induced by a control module.
- a control module energizes a magnetic field in the magnetic particle brake or the magnetorheological fluid device causing the magnetic particle brake or the magnetorheological fluid device in turn to provide variable passive resistance.
- the variable passive resistance along with active resistance provided by the electric motor gives the vehicle operator a feel of the road by transferring the resistance upon the steering wheel. Thus, causing the vehicle operator to “feel” or sense the road.
- the handwheel actuator 100 illustrates generally a stop mechanism 126 enclosed by housing 130 and comprising the spur gear 110 of the gear train 104 geared to a reducing spur gear 132 .
- Reducing gear 132 further comprises interior arcuate stop guides 126 a , 126 b , one on either side of the gear 132 having a first stop pin 126 c disposed within said stop guide 126 a and having a having a second stop pin 126 d disposed within stop guide 126 b , such that as spur gear 110 rotates, reducing gear 132 , and thus spur gear 110 , is mechanically restrained as the first stop pin and second stop pin make simultaneous contact with one pair of two ends 126 e , 126 f of one end of the interior arcuate stop guides 126 a , 126 b (See FIG.
- the other end of the internal arcuate stop guides 126 a , 126 b is not shown.
- the first stop pin and second stop pin are attached to the housing 130 .
- the stop pins 126 c , 126 d are rubber coated and provide over 100 Nm of overload torque capability.
- a modular unit 140 is attached to the shaft 102 that acts as a mechanical back-up device to provide auxiliary steering resistance in the steer-by-wire system 600 .
- Modular unit 140 allows full lock-to-lock travel of the steering handwheel 10 while providing torsional resistance to handwheel rotation up to a specified saturation torque.
- Modular unit 140 provides an adjustable on-center feel and return-to-center mechanism for the steer-by-wire handwheel actuator 100 to provide a passive steering system feel similar to current production hydraulic assisted rack and pinion systems.
- Modular unit 140 provides the driver with force feedback throughout the range of travel of the handwheel 10 .
- Modular unit 140 comprises a ball screw assembly 142 including a hollow sleeve 144 that slip fits over the ball screw assembly 142 and is rotationally fixed using an anti-rotation pin assembly 148 and a key 149 opposite thereto.
- Rotation pin assembly 148 includes a pin 150 slidably engaged against an exterior sleeve 144 .
- Anti-rotation pin assembly 148 further includes a pin retainer 152 and screw 154 that is disposed in an aperture 156 of retainer 152 and received in a threaded aperture 158 of housing 162 defining modular unit 140 .
- Pin 150 is configured with a slot 163 positioned thereon to allow a portion of retainer 152 to be received therein while maintaining pin 150 slidably disposed in an aperture formed in housing 162 to engage an outside surface of a sleeve 144 when screw 154 is fixed against retainer 152 by tightening screw 154 in threaded aperture 158 .
- Sleeve 144 has a channel 164 configured on a periphery thereof to allow axial translation of sleeve 144 while limiting rotation thereof.
- Sleeve 144 engages a threaded portion 166 of shaft 102 via a ball nut 168 disposed in sleeve 144 .
- Ball nut 168 is retained in sleeve 144 with a ball nut retainer nut 169 .
- Ball nut 168 has complementary threads to engage threaded portion 166 .
- Screw shaft 102 is supported in a ball bearing assembly 170 that is disposed at one end in housing 162 .
- Bearing assembly 170 is retained in housing 162 with a bearing cap 172 that is mechanically fastened to housing 162 with mechanical fasteners 174 .
- a bearing nut 176 is engageable with another threaded portion of shaft 102 to fix shaft 102 relative to bearing assembly 170 which is fixed relative to housing 162 .
- an end cap 180 encloses a cavity formed in housing 162 .
- a retaining nut 182 is threaded onto the end of sleeve 144 and an external spring return nut 196 is threaded into housing 162 .
- a first spring retaining washer 188 Disposed against retaining nut 196 and retaining nut 182 is a first spring retaining washer 188 having an aperture allowing ball screw 144 to slide therethrough.
- a second spring retaining washer 190 is disposed against a shoulder 192 of sleeve 144 and shoulder 198 of housing 162 . Like washer 188 , washer 190 includes an aperture that allows sleeve 144 to slide therethrough.
- a plurality of biasing members 194 is disposed intermediate washers 188 , 190 . Each biasing member is preferably a disc spring or Belleville washer.
- the plurality of biasing members 194 is more preferably a stack of disc springs circumferentially disposed about sleeve 144 while allowing translation of sleeve 144 therethrough.
- the stack of disc springs are preferably formed by alternating the orientation of contiguous disc springs to provide a compression type biasing member 194 .
- the spring pack or plurality of biasing members 194 is stacked in series to provide desired spring load and maximum travel. The springs are designed and preferably preloaded to a stack height that gives a non-linear spring rate with a very gradual slope.
- Spring retaining nut 182 is preferably configured as an adjustment preload nut that is threaded onto the sleeve 144 and tightened to a specified position to set the appropriate spring preload on the biasing members 194 .
- An external spring return nut 196 has exterior threads threadably engaged with complementary threads in housing 162 at end 178 for engaging washer 188 when sleeve 144 translates toward end 178 pushing washer 192 to compress biasing members 194 which push against washer 188 which is prevented from translating toward end 178 by fixed nut 196 .
- biasing members 194 When sleeve 144 translates away from end 178 , nut 182 pushes against washer 188 to compress biasing members 194 against washer 192 that is prevented from translating away from end 178 by a shoulder 198 formed in housing 162 .
- the preload on the biasing members 194 is configured to provide an identical bias when shaft 102 is rotated in either direction since the spring pack or plurality of biasing members 194 is configured in a parallel arrangement to bias the shaft indicative of a return-to-center position. It will be recognized that although the plurality of biasing members has been described as a single series stack of disc washers, multiple stacks are also contemplated.
- a first stack may be disposed on one side of ball nut 168 while a second stack is disposed on the other side of ball nut 168 .
- first stack when shaft is rotated in one direction, the first stack is compressed and when shaft 102 is rotated in an opposite direction, the second stack is compressed.
- the steering shaft 102 rotates at the same speed.
- the ball nut 168 and hence sleeve 144 translates left or right in an axial direction relative to shaft 102 shown in FIG. 9 depending on direction of rotation.
- the axial load increase reflects through the ball nut 168 giving an increasing torque feed back to the driver as the hand wheel 10 is turned further from center.
- the mechanism will not run out of travel since the hand wheel actuator will reach its end of travel stop before maximum travel of the ball nut 168 is reached.
- the ball nut 168 will backdrive on the screw due to the axial load imbalance until it reaches the equilibrium load at the center position.
- FIG. 4 a preferred embodiment depicted in FIG. 3 is shown from the rear, and FIG. 5 illustrates the front/plan view of FIG. 4 .
- FIG. 5 also illustrates three cross sections taken for the Figures referenced above that follow.
- FIGS. 4 and 5 illustrate the housing 130 coupled to a bracket 160 for attaching a handwheel actuator to a vehicle mounting interface.
- the handwheel actuator 100 is operative to accept as input thereto, firstly, steering commands by way of the driver input shaft 102 from an outside motive source such as a driver 500 , secondly, the first control signal 100 a from the controller 400 to the motor 114 and thirdly, a second control signal 100 b from the controller 400 to the electro-mechanical brake 120 .
- the steering commands are typically the clockwise or counterclockwise rotation of the driver input shaft 102 .
- the first control signal 100 a originating from the controller 400 controls the input to the speed reducer pulley 124 by the motor 114 .
- the second control signal 100 b controls a feedback torque directed to the driver input shaft 102 by the electro-mechanical brake 120 .
- the first control signal 100 a based upon the changing operating conditions, activates the motor 114 so as to control speed reducer pulley 124 , namely resisting or assisting to the motion of reducing pulley 108 and allowing controlled rotation thereof.
- the second control signal 100 b from the controller 400 activates the electro-mechanical brake 120 so as to provide a resistive torque to the speed reducer 104 by way of the engagement of the electro-mechanical brake 120 to the driver input shaft 102 through the electro-mechanical brake shaft 122 , the pulley 124 , belt 136 , and the driver feedback pulley 106 .
- the resistive torque results in a feedback torque that provides the driver 500 with additional tactile response to steering commands.
- Motor 114 is in direct drive relationship with motor shaft 116 operably connected to shaft 102 absent a connection via a speed reducer.
- Motor 114 includes a motor stator 206 surrounding a motor rotor 208 operably connected to shaft 116 for rotation thereof when rotor 206 is energized.
- Motor shaft 116 is connected to driver input shaft 102 via a sleeve assembly 212 having a torsion bar 214 disposed therein for torque sensing by torque sensor 22 .
- Sleeve assembly 212 is connected to a worm gear 216 that is engaged to a worm 218 .
- Worm 218 is rotatably supported between two bearings 222 and is operably connected to brake 120 via shaft 122 at one end thereof.
- brake 120 provides up to about 6 Nm of torque feedback by braking that is transmitted to worm 218 , worm gear 216 , to sleeve assembly 212 , and then to driver input shaft 102
- motor 114 provides up to about 4 Nm of torque feedback in conjunction with the 6 Nm from brake 120 to driver input shaft for a total of up to about 10 Nm.
- Motor 114 generates the torque through shaft 116 , to sleeve assembly 212 , and then to the driver input shaft 102 .
- worm and worm gear drive with the direct drive motor connection, zero lash and comparable noise are experienced compared with the belt drive previously described above.
Abstract
A steer-by-wire handwheel actuator in a vehicle is presented. The handwheel actuator comprises a driver input shaft; a gear train connected to the driver input shaft; a motor responsive to control signals from a controller and variably geared to the gear train; a electro-mechanical brake responsive to the control signals from the controller and geared to one of the driver input shaft and the gear train; and a stop mechanism attached to a housing and coupled to one of the electro-mechanical brake and the gear train.
Description
- This application claims the benefit of U.S. provisional application No. 60/299,342, filed Jun. 19, 2001 the contents of which are incorporated by reference herein in their entirety.
- This invention relates to a steer-by-wire system, and more particularly to a steer-by-wire handwheel actuator.
- It is known in the art to have a steering system with mechanical linkage from the steering wheel to the steerable road wheels. Even with power assist, the driver of a mechanically linked vehicle can feel the forces of the road against the steerable wheels through the steering wheel. Indeed, this is a desired feature of direct linkage and is sought out by purchasers of high performance vehicles in the form of so-called “rack-and-pinion” steering. The road forces felt in the steering wheel give the driver feedback he can use to anticipate and control the vehicle, or at least create the comfortable feeling that he is in control of the vehicle. Remove this feedback, such as in the case of “mushy” power steering, and the driver will have the uncomfortable feeling of being separated from the road wheels, not quite in control, and will tend to oversteer his vehicle, particularly in demanding situations such as sharp or sudden turns.
- By definition, a steer-by-wire system has no mechanical link connecting the steering wheel from the road wheels. In effect, the steering wheel is little more than a joystick, albeit an extremely sophisticated joystick. Exemplary of such known steer-by-wire systems is commonly-assigned U.S. Pat. No. 6,176,341, issued Jan. 23, 2001 to Ansari, which is wholly incorporated herein by reference. What is needed is to provide the steer-by-wire driver with the same “road feel” that a driver receives with a direct mechanical link. Furthermore, it is desirable to have a device that provides a mechanical back up “road feel” in the event of multiple electronic failures in the steer-by-wire system. In addition, a device that provides positive on-center feel and accurate torque variation as the handwheel is rotated is also desirable. Existing steer-by-wire devices produce excessive lash, excessive noise and insufficient over-load torque capability as the handwheel is rotated to its end of travel in either direction.
- A steer-by-wire steering system is defined as a steering system with no mechanical connection between a steering wheel and a set of steering gears or actuators. Such systems are advantageous because they permit auto and other vehicle designers great latitude in use of space that would normally be taken up by mechanical linkages, among other reasons.
- In an exemplary embodiment of the invention, a steer-by-wire handwheel actuator is described, which provides feedback of road forces to the operator of a steer-by-wire vehicle. A handwheel actuator comprises a driver input shaft; a gear train connected to the driver input shaft; a motor responsive to control signals from a controller and connected to the gear train; an electro-mechanical brake responsive to the control signals from the controller and connected to one of the driver input shaft and the gear train; and a stop mechanism attached to a housing and coupled to one of the electro-mechanical brake and the gear train.
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FIG. 1 is a perspective view of a prior art hard contact driving system; -
FIG. 2 is a schematic representation of the steer-by-wire handwheel actuator in signal communication with a steer-by-wire steering system; -
FIG. 3 is a perspective view of an exemplary embodiment of a steer-by-wire handwheel actuator; -
FIG. 4 is a rear/plan view of a an exemplary embodiment of a steer-by-wire handwheel actuator ofFIG. 3 ; -
FIG. 5 is a front /plan view of a an exemplary embodiment of a steer-by-wire handwheel actuator shown inFIG. 4 detailing cross sectional divisions that follow; -
FIG. 6 is a cross section view of an exemplary embodiment of a steer-by-wire handwheel actuator depicted inFIG. 5 , Section 6-6; -
FIG. 7 is a cross section view of an exemplary embodiment of a steer-by-wire handwheel actuator depicted inFIG. 5 , Section 7-7; -
FIG. 8 is a cross section view of an exemplary embodiment of a steer-by-wire handwheel actuator depicted inFIG. 5 , Section 8-8; -
FIG. 9 is a cross section view of a modular unit attached to a steering shaft to provide auxiliary steering resistance; -
FIG. 10 is a cross section view of an alternative embodiment of the steer-by-wire handwheel actuator ofFIG. 3 with a combination worm gear and direct drive power transmission; and -
FIG. 11 is another cross section view of the alternative embodiment of the steer-by-wire handwheel actuator ofFIG. 10 with worm gear power transmission taken perpendicular to the view ofFIG. 10 . - Referring to
FIG. 1 , a typical prior art steering system is depicted. Asteering wheel 10 is connected to asteering column 11 which in turn is connected to a steeringintermediate shaft 12 viauniversal joint 14. Anotheruniversal joint 16 couplesintermediate steering shaft 12 to an electric power steering assist assembly (rack assist) 18. It is evident that mechanical direct connection exists throughout the prior art driving system. -
FIG. 2 is a schematic representation of a steer-by-wire steering system 600 as it is comprises acontroller 400, a first electro-mechanical actuator 202 and a second electro-mechanical actuator 302, eachactuator signal communication controller 400. In one embodiment, the first and second electro-mechanical actuators first wheel 200 and asecond wheel 300 and are operative thereby to steer thewheels controller 400. In another embodiment, it will be appreciated by one skilled in the pertinent art that one actuator is optionally linked to bothroad wheels wheels - Still referring to
FIG. 2 , ahandwheel actuator 100 of the present disclosure is insignal communication controller 400 of the steer-by-wire steering system 600.Handwheel actuator 100 is in further communication with anexternal motive source 500, such as a driver from whom thehandwheel actuator 100 receives steering commands by way of adriver input shaft 102. Thecontroller 400 is also operative to receive as input thereto asignal 700 indicative of vehicle velocity, as well as asignal 500 a indicative of the position of thedriver input shaft 102 and asignal 500 b indicative of the torque on thedriver input shaft 102.Signals handwheel actuator 100proximate shaft 102. - With reference to
FIG. 3 , therein depicted is a representation of thehandwheel actuator 100 of a preferred embodiment. Thehandwheel actuator 100 includes ahousing 130, adriver input shaft 102 and agear train 104 coupled to thedriver input shaft 102. In the interest of clarity, thegear train 104 comprises adriver feedback pulley 106, aspeed reducer pulley 108, and a spur gear 110 (See alsoFIG. 7 , asgear train 104 is shaded completely). Thedriver input shaft 102 is rotatably positioned between an upper bearing 54 and alower bearing 56, andposition sensors 20 andtorque sensor 22 operably connected todriver input shaft 102.Position sensors 20 electronically detect the angular position of thedriver input shaft 102, while thetorque sensor 22 electronically detects and evaluates the torsional force acting on thedriver input shaft 102. The angular displacement of thehand steering wheel 10 is detected bysensors handwheel actuator 100 ofFIGS. 3 and 6 includes anelectric motor 114 having amotor shaft 116 rotatively driven by themotor 114. Attached or optionally formed into themotor shaft 116 is amotor pulley 118. Attached to themotor pulley 118 is abelt 128 positively drivingpulley 108 of thegear train 104. Continuing inFIG. 3 in conjunction withFIG. 7 , thehandwheel actuator 100 further includes an electro-mechanical brake 120 having an electro-mechanical brake shaft 122 rotatively controlled by the electro-mechanical brake 120. Attached or optionally formed into the electro-mechanical brake shaft 122 is apulley 124 driving abelt 136 operably connected to thegear train 104. More specifically, thebelt 136 is connected to thedriver feedback pulley 106 in an exemplary embodiment. - It should be noted that a preferred embodiment of the handwheel actuator utilizes an electric sine commutated
brushless motor 114 for its primary power transmission because the sine wave commutation provides for a low torque ripple. Furthermore, it is preferred that thebelt 128 used to transmit the power from themotor 114 is a small-cogged belt to provide positive drive, high efficiency, low noise, and nearly zero lash. In using a cogged belt, it has been found to yield approximately 98% efficiency. In addition, a preferred embodiment uses a magnetic particle brake for the electro-mechanical brake 120, however alternative embodiments also include electro-rheological fluid devices. - Magnetorheological fluids suitable for use in the
handwheel actuator 100 are disclosed in U.S. Pat. No. 5,896,965, issued 27 Apr. 1999, to Gopalswamy et al. for a Magnetorheological Fluid Fan Clutch; U.S. Pat. No. 5,848,678, issued 15 Dec. 1998, to Johnston et al. for a Passive Magnetorheological Clutch; U.S. Pat. No. 5,845,752, issued 8 Dec. 1998, to Gopalswamy et al. for a Magnetorheological Fluid Clutch with Minimized Resistance; U.S. Pat. No. 5,823,309, issued 20 Oct. 1998, to Gopalswamy et al. for a Magnetorheological Transmission Clutch; and U.S. Pat. No. 5,667,715, issued 16 Sep. 1997, to Foister, R. T. for Magnetorheological Fluids; the disclosures of all of which are incorporated herein by reference in their entirety. An alternative embodiment utilizing an electro-rheological fluid device having magnetorheological fluid for obtaining a variable resistance to the driver input shaft is disclosed in Patent Application number DP-300272, entitled “Variable Road Feedback Device For Steer-By-Wire System.” - It is to be noted that utilizing a magnetic particle brake or a magnetorheological fluid device provides virtually no resistance to a driver input shaft when there is no magnetic force induced by a control module. However, when it becomes desirable to give the vehicle operator a feel of the road, a control module energizes a magnetic field in the magnetic particle brake or the magnetorheological fluid device causing the magnetic particle brake or the magnetorheological fluid device in turn to provide variable passive resistance. The variable passive resistance along with active resistance provided by the electric motor gives the vehicle operator a feel of the road by transferring the resistance upon the steering wheel. Thus, causing the vehicle operator to “feel” or sense the road.
- Returning to
FIG. 3 and incorporatingFIG. 8 , thehandwheel actuator 100 illustrates generally astop mechanism 126 enclosed byhousing 130 and comprising thespur gear 110 of thegear train 104 geared to a reducingspur gear 132. Reducinggear 132 further comprises interior arcuate stop guides 126 a, 126 b, one on either side of thegear 132 having afirst stop pin 126 c disposed within saidstop guide 126 a and having a having asecond stop pin 126 d disposed withinstop guide 126 b, such that asspur gear 110 rotates, reducinggear 132, and thus spurgear 110, is mechanically restrained as the first stop pin and second stop pin make simultaneous contact with one pair of twoends 126 e, 126 f of one end of the interior arcuate stop guides 126 a, 126 b (SeeFIG. 8 ). The other end of the internal arcuate stop guides 126 a, 126 b is not shown. The first stop pin and second stop pin are attached to thehousing 130. In an exemplary embodiment, the stop pins 126 c, 126 d are rubber coated and provide over 100 Nm of overload torque capability. - Still referring to
FIG. 3 , amodular unit 140 is attached to theshaft 102 that acts as a mechanical back-up device to provide auxiliary steering resistance in the steer-by-wire system 600.Modular unit 140 allows full lock-to-lock travel of thesteering handwheel 10 while providing torsional resistance to handwheel rotation up to a specified saturation torque. - Referring to
FIG. 9 ,modular unit 140 is shown in more detail and described below.Modular unit 140 provides an adjustable on-center feel and return-to-center mechanism for the steer-by-wire handwheel actuator 100 to provide a passive steering system feel similar to current production hydraulic assisted rack and pinion systems.Modular unit 140 provides the driver with force feedback throughout the range of travel of thehandwheel 10.Modular unit 140 comprises aball screw assembly 142 including ahollow sleeve 144 that slip fits over theball screw assembly 142 and is rotationally fixed using ananti-rotation pin assembly 148 and a key 149 opposite thereto.Rotation pin assembly 148 includes apin 150 slidably engaged against anexterior sleeve 144.Anti-rotation pin assembly 148 further includes apin retainer 152 and screw 154 that is disposed in an aperture 156 ofretainer 152 and received in a threaded aperture 158 ofhousing 162 definingmodular unit 140.Pin 150 is configured with aslot 163 positioned thereon to allow a portion ofretainer 152 to be received therein while maintainingpin 150 slidably disposed in an aperture formed inhousing 162 to engage an outside surface of asleeve 144 whenscrew 154 is fixed againstretainer 152 by tighteningscrew 154 in threaded aperture 158.Sleeve 144 has achannel 164 configured on a periphery thereof to allow axial translation ofsleeve 144 while limiting rotation thereof.Sleeve 144 engages a threadedportion 166 ofshaft 102 via aball nut 168 disposed insleeve 144.Ball nut 168 is retained insleeve 144 with a ballnut retainer nut 169.Ball nut 168 has complementary threads to engage threadedportion 166.Screw shaft 102 is supported in aball bearing assembly 170 that is disposed at one end inhousing 162. -
Bearing assembly 170 is retained inhousing 162 with abearing cap 172 that is mechanically fastened tohousing 162 withmechanical fasteners 174. A bearingnut 176 is engageable with another threaded portion ofshaft 102 to fixshaft 102 relative to bearingassembly 170 which is fixed relative tohousing 162. At anopposite end 178 ofhousing 162 anend cap 180 encloses a cavity formed inhousing 162. At the same end 178 a retainingnut 182 is threaded onto the end ofsleeve 144 and an externalspring return nut 196 is threaded intohousing 162. Disposed against retainingnut 196 and retainingnut 182 is a firstspring retaining washer 188 having an aperture allowingball screw 144 to slide therethrough. A secondspring retaining washer 190 is disposed against ashoulder 192 ofsleeve 144 andshoulder 198 ofhousing 162. Likewasher 188,washer 190 includes an aperture that allowssleeve 144 to slide therethrough. A plurality of biasingmembers 194 is disposedintermediate washers members 194 is more preferably a stack of disc springs circumferentially disposed aboutsleeve 144 while allowing translation ofsleeve 144 therethrough. The stack of disc springs are preferably formed by alternating the orientation of contiguous disc springs to provide a compressiontype biasing member 194. The spring pack or plurality of biasingmembers 194 is stacked in series to provide desired spring load and maximum travel. The springs are designed and preferably preloaded to a stack height that gives a non-linear spring rate with a very gradual slope. -
Spring retaining nut 182 is preferably configured as an adjustment preload nut that is threaded onto thesleeve 144 and tightened to a specified position to set the appropriate spring preload on the biasingmembers 194. An externalspring return nut 196 has exterior threads threadably engaged with complementary threads inhousing 162 atend 178 for engagingwasher 188 whensleeve 144 translates towardend 178 pushingwasher 192 to compress biasingmembers 194 which push againstwasher 188 which is prevented from translating towardend 178 by fixednut 196. Whensleeve 144 translates away fromend 178,nut 182 pushes againstwasher 188 to compress biasingmembers 194 againstwasher 192 that is prevented from translating away fromend 178 by ashoulder 198 formed inhousing 162. The preload on the biasingmembers 194 is configured to provide an identical bias whenshaft 102 is rotated in either direction since the spring pack or plurality of biasingmembers 194 is configured in a parallel arrangement to bias the shaft indicative of a return-to-center position. It will be recognized that although the plurality of biasing members has been described as a single series stack of disc washers, multiple stacks are also contemplated. More specifically, it is contemplated that a first stack may be disposed on one side ofball nut 168 while a second stack is disposed on the other side ofball nut 168. In this manner, when shaft is rotated in one direction, the first stack is compressed and whenshaft 102 is rotated in an opposite direction, the second stack is compressed. - In operation, as the
hand wheel 10 is rotated from the center position, the steeringshaft 102 rotates at the same speed. As thesteering shaft 102 rotates, theball nut 168 and hencesleeve 144 translates left or right in an axial direction relative toshaft 102 shown inFIG. 9 depending on direction of rotation. When thesleeve 144 translates it compresses the spring stack giving a gradual load increase on theball nut 168. The axial load increase reflects through theball nut 168 giving an increasing torque feed back to the driver as thehand wheel 10 is turned further from center. The mechanism will not run out of travel since the hand wheel actuator will reach its end of travel stop before maximum travel of theball nut 168 is reached. When the driver releases thehand wheel 10 theball nut 168 will backdrive on the screw due to the axial load imbalance until it reaches the equilibrium load at the center position. - Turning to
FIG. 4 , a preferred embodiment depicted inFIG. 3 is shown from the rear, andFIG. 5 illustrates the front/plan view ofFIG. 4 .FIG. 5 also illustrates three cross sections taken for the Figures referenced above that follow.FIGS. 4 and 5 illustrate thehousing 130 coupled to abracket 160 for attaching a handwheel actuator to a vehicle mounting interface. - In
FIG. 2 , in conjunction withFIGS. 6 and 7 , thehandwheel actuator 100 is operative to accept as input thereto, firstly, steering commands by way of thedriver input shaft 102 from an outside motive source such as adriver 500, secondly, the first control signal 100 a from thecontroller 400 to themotor 114 and thirdly, asecond control signal 100 b from thecontroller 400 to the electro-mechanical brake 120. The steering commands are typically the clockwise or counterclockwise rotation of thedriver input shaft 102. The first control signal 100 a originating from thecontroller 400 controls the input to thespeed reducer pulley 124 by themotor 114. Thesecond control signal 100 b controls a feedback torque directed to thedriver input shaft 102 by the electro-mechanical brake 120. - In
FIGS. 6 and 7 , the clockwise or counterclockwise rotation of thedriver input shaft 102 instigates the action of thespeed reducer pulley 124. By way ofpulley 108 themotor shaft 116 is positively driven bybelt 128. Such engagement results in a gear ratio, R1, of thespeed reducer pulley 124. As vehicular operating conditions change, e.g., a change in vehicular speed or a change in the position of thedriver input shaft 102, plus the application of road forces acting upon the steer-by-wire system 600 (SeeFIG. 2 ), the first control signal 100 a, based upon the changing operating conditions, activates themotor 114 so as to controlspeed reducer pulley 124, namely resisting or assisting to the motion of reducingpulley 108 and allowing controlled rotation thereof. Based upon the aforesaid changing operating conditions, thesecond control signal 100 b from thecontroller 400 activates the electro-mechanical brake 120 so as to provide a resistive torque to thespeed reducer 104 by way of the engagement of the electro-mechanical brake 120 to thedriver input shaft 102 through the electro-mechanical brake shaft 122, thepulley 124,belt 136, and thedriver feedback pulley 106. The resistive torque results in a feedback torque that provides thedriver 500 with additional tactile response to steering commands. - Referring now to
FIGS. 10 and 11 , an alternative embodiment for eliminatingpulleys corresponding belts Motor 114 is in direct drive relationship withmotor shaft 116 operably connected toshaft 102 absent a connection via a speed reducer.Motor 114 includes amotor stator 206 surrounding amotor rotor 208 operably connected toshaft 116 for rotation thereof whenrotor 206 is energized.Motor shaft 116 is connected todriver input shaft 102 via asleeve assembly 212 having atorsion bar 214 disposed therein for torque sensing bytorque sensor 22.Sleeve assembly 212 is connected to aworm gear 216 that is engaged to aworm 218.Worm 218 is rotatably supported between twobearings 222 and is operably connected to brake 120 viashaft 122 at one end thereof. In an exemplary embodiment,brake 120 provides up to about 6 Nm of torque feedback by braking that is transmitted toworm 218,worm gear 216, tosleeve assembly 212, and then todriver input shaft 102, whilemotor 114 provides up to about 4 Nm of torque feedback in conjunction with the 6 Nm frombrake 120 to driver input shaft for a total of up to about 10 Nm.Motor 114 generates the torque throughshaft 116, tosleeve assembly 212, and then to thedriver input shaft 102. Using the worm and worm gear drive with the direct drive motor connection, zero lash and comparable noise are experienced compared with the belt drive previously described above. - It will be understood that a person skilled in the art may make modifications to the preferred embodiment shown herein within the scope and intent of the claims. While the present invention has been described as carried out in a specific embodiment thereof, it is not intended to be limited thereby but intended to cover the invention broadly within the scope and spirit of the claims.
Claims (6)
1. A steer-by-wire handwheel actuator utilizing a controller operative to accept as input thereto data from the steer-by-wire system and generate therefrom control signals in a vehicle comprising:
a driver input shaft;
a gear train connected to the driver input shaft;
a motor responsive to the control signals from the controller and variably geared to the gear train, the motor including a motor shaft driven therefrom and a motor pulley connected to the motor shaft and having cogs circumferentially arranged;
an electro-mechanical brake responsive to the control signals from the controller and geared to one of the driver input shaft and the gear train; and
a stop mechanism attached to a housing and coupled to one of the electro-mechanical brake and the gear train,
wherein the gear train is a pulley and gear train assembly, said gear train assembly including:
a driver feedback pulley connected to the driver input shaft;
a speed reducer pulley having cogs circumferentially arranged for positive engagement with the motor pulley cogs and being connected to the driver input shaft; and
a spur gear connected to the driver input shaft.
2-3. (canceled)
4. The steer-by-wire handwheel actuated as set forth in claim 1 wherein the speed reducer pulley and the motor pulley are positively engages via a cogged belt.
5. The steer-by-wire handwheel actuator as set forth in claim 1 further comprising:
a modular unit having a biasing member to provide mechanical resistance to one of the driver input shaft and the gear train.
6. The steer-by-wire handwheel actuator as set forth in claim 5 wherein the modular unit includes a ball nut assembly operably connected to said driver input shaft.
7. The steer-by-wire handwheel actuator as set forth in claim 6 wherein said ball nut assembly is biased in a predetermined position corresponding to an on center steering position.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US10/988,472 US20050087384A1 (en) | 2001-06-19 | 2004-11-12 | Steer-by-wire handwheel actuator |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US29934201P | 2001-06-19 | 2001-06-19 | |
US10/163,927 US6817437B2 (en) | 2001-06-19 | 2002-06-06 | Steer-by wire handwheel actuator |
US10/988,472 US20050087384A1 (en) | 2001-06-19 | 2004-11-12 | Steer-by-wire handwheel actuator |
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US10/163,927 Continuation US6817437B2 (en) | 2001-06-19 | 2002-06-06 | Steer-by wire handwheel actuator |
Publications (1)
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US20050087384A1 true US20050087384A1 (en) | 2005-04-28 |
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US10/163,927 Expired - Fee Related US6817437B2 (en) | 2001-06-19 | 2002-06-06 | Steer-by wire handwheel actuator |
US10/988,472 Abandoned US20050087384A1 (en) | 2001-06-19 | 2004-11-12 | Steer-by-wire handwheel actuator |
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Application Number | Title | Priority Date | Filing Date |
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US10/163,927 Expired - Fee Related US6817437B2 (en) | 2001-06-19 | 2002-06-06 | Steer-by wire handwheel actuator |
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US (2) | US6817437B2 (en) |
WO (1) | WO2002102640A2 (en) |
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US20090194363A1 (en) * | 2008-02-05 | 2009-08-06 | Crown Equipment Corporation | Materials handling vehicle having a steer system including a tactile feedback device |
US7849955B2 (en) | 2008-02-05 | 2010-12-14 | Crown Equipment Corporation | Materials handling vehicle having a steer system including a tactile feedback device |
US7980352B2 (en) | 2008-02-05 | 2011-07-19 | Crown Equipment Corporation | Materials handling vehicle having a steer system including a tactile feedback device |
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US8412431B2 (en) | 2008-02-05 | 2013-04-02 | Crown Equipment Corporation | Materials handling vehicle having a control apparatus for determining an acceleration value |
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Also Published As
Publication number | Publication date |
---|---|
WO2002102640A3 (en) | 2003-11-20 |
US20020189888A1 (en) | 2002-12-19 |
WO2002102640A2 (en) | 2002-12-27 |
US6817437B2 (en) | 2004-11-16 |
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Legal Events
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