Electric power assist module for steering system

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

the motor includes a body and a rotatable drive shaft that protrudes from the body, and

the motor being at least partially contained by the integrated housing comprises the body being at least partially contained by the integrated housing;

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.

2. The electric power assist module according to claim 1 , comprising a side cover, wherein:

the integrated housing defines a cavity with a side opening;

the side cover substantially hermetically closes the side opening; and

the electronic control unit is positioned in the cavity.

3. The electric power assist module according to claim 1 , wherein:

the pinion gear is carried by a carrying shaft having opposite first and second ends;

the first end of the carrying shaft is mated to the drive shaft; and

the second end of the carrying shaft is supported in the lower housing.

4. The electric power assist module according to claim 1 , wherein:

the pinion gear is meshed with a first gear of the intermediate gear;

a second gear of the intermediate gear is meshed with the steering gear;

the first gear of the intermediate gear has a helix angle;

the second gear of the intermediate gear has a helix angle;

the intermediate gear is carried by a carrying shaft having opposite first and second ends;

the first end of the carrying shaft is supported in the integrated housing;

the second end of the carrying shaft is supported in the lower housing; and

the steering gear is press fit onto the output shaft.

5. The electric power assist module according to claim 1 , comprising a first bearing and a second bearing, wherein:

the first bearing is supported by the integrated housing;

the second bearing is supported by the lower housing; and

the output shaft is rotatably carried by each of the first and second bearings.

6. The electric power assist module according to claim 1 , wherein:

the input shaft and the output shaft are operatively associated with one another via a cavity being in receipt of a profile; and

the cavity and the profile are cooperative for allowing, yet restricting to a predetermined limit, relative rotation between the input shaft and the output shaft.

7. The electric power assist module according to claim 6 , wherein the cavity and the profile are each substantially triangular.

8. The electric power assist module according to claim 1 , wherein:

the electronic control unit comprises a processing apparatus;

the processing apparatus is operatively associated with the torque sensor for receiving signals indicative of torque applied to the input shaft;

the processing apparatus is operative for generating a pulse width modulation signal that is proportional to the torque applied to the input shaft; and

the motor operates responsively to the pulse width modulation signal.

9. The electric power assist module according to claim 1 in combination with at least:

an upper shaft, a lower shaft, a rack and pinion mechanism, and a steering shaft, wherein

the upper shaft comprises two universal joints;

the lower shaft comprises two universal joints;

the upper shaft is positioned between and connected to each of the steering shaft and the input shaft;

the lower shaft is positioned between and connected to each of the output shaft and a pinion gear of the rack and pinion mechanism;

axes of the pinion gear of the rack and pinion mechanism and the output shaft are in different planes; and

axes of the steering shaft and the input shaft are in different planes.

10. The electric power assist module according to claim 1 , wherein:

the torque sensor is for providing a signal that is indicative of torque applied to the input shaft;

the electronic control unit is for providing a pulse width modulation signal in response to at least the signal from the torque sensor; and

the motor is for driving the reduction gear assembly in response to at least the pulse width modulation signal.

11. The electric power assist module according to claim 1 , wherein:

the pinion gear is connected to the drive shaft of the motor so that the pinion gear rotates with the drive shaft;

the pinion gear is meshed with a first gear of the intermediate gear;

the steering gear is meshed with a second gear of the intermediate gear;

the first gear of the intermediate gear is connected to the second gear of the intermediate gear so that the second gear of the intermediate gear rotates with the first gear of the intermediate gear;

the first gear of the intermediate gear has a helix angle;

the second gear of the intermediate gear has a helix angle; and

the steering gear is connected to the output shaft so that the output shaft rotates with the steering gear.

12. The electric power assist module according to claim 1 , wherein:

the integrated housing defines a passageway between the electronic control unit and each of the torque sensor and the motor; and

both the first electrical connection and the second electrical connection extend through the passageway.

13. An electric power assist module for a steering system, with the electric power assist module comprising:

an integrated housing comprising an upper chamber and a side chamber that is beside and contiguous with the upper chamber, wherein the upper chamber includes an upper opening;

a torque sensor contained in the upper chamber;

a motor, wherein

the motor includes a body and a drive shaft that protrudes from the body,

the body includes a first portion,

the body includes a second portion, and

the second portion of the body of the motor is contained in the upper chamber so that the second portion of the body of the motor is adjacent to the torque sensor within the upper chamber;

an electronic control unit at least partially contained in the side chamber;

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;

an upper cover mounted to the integrated housing for closing the upper opening of the upper chamber, wherein the upper cover includes

a first opening, wherein the input shaft is rotatably mounted to the upper cover and extends through the first opening, and

a second opening, wherein the first portion of the body of the motor extends through the second opening;

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; and

a lower housing that is mounted to the integrated housing, wherein

the lower housing at least partially contains the helical gear train, and

the output shaft is rotatably mounted to the lower housing and extends through an opening of the lower housing so that

the output shaft is aligned with the input shaft, and

the output shaft projects downwardly away from the lower housing.

14. The electric power assist module according to claim 13 , wherein the integrated housing is formed as a single piece.

15. The electric power assist module according to claim 14 , comprising

the integrated housing including a passageway that extends between, and extends to each of, the upper chamber and the side chamber;

a first electrical connection that extends from the electronic control unit to the torque sensor;

a second electrical connection that extends from the electronic control unit to the motor; and

each of the first electrical connection and the second electrical connection extending through the passageway of the integrated housing.