CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority under 35 U.S.C. § 119 to United States

Provisional Patent Application No. 62/513,023, filed May 31, 2017.

FIELD OF THE INVENTION

[0002] The present invention relates to a plunger assembly and, more particularly, to a plunger assembly used in a hydraulic power steering system.

BACKGROUND

[0003] Power steering systems using hydraulic pressure to assist steering the wheels of a vehicle are known in the art. An input steering shaft of known power steering systems is connected to a piston disposed in a chamber defined by a housing; rotational motion of the input steering shaft moves the piston along the chamber. A hydraulic fluid is disposed in the chamber and is used to provide an additional pressure force moving the piston along the chamber. Motion of the piston imparts motion to an output shaft, which steers the wheels of the vehicle.

[0004] Such a power steering system is described in U.S. Patent No. 5,803,201 and shown generally in Figure 1. In the power steering system 100, the input steering shaft 110 extends through a bearing cap 120 disposed on an end of the body 130, the bearing cap 120 and the body 130 form the housing 120, 130 defining the chamber 140. Hydraulic pressure builds in either the first portion 140a or the second portion 140b of the chamber 140 to assist motion of the piston 150 in either direction within the chamber 140.

[0005] As the piston 150 is moved by the input steering shaft 110, to prevent a wheel knuckle on an axle of the power steering system from hitting an axle stop under hydraulic pressure, the power steering system 100 includes a plunger 160 disposed in a bore 170a, 170b at each end of the chamber 140. The plunger 160 engages a valve 152 of the piston 150 as the piston 150 nears an end of travel at each end of the chamber 140 corresponding to the axle stop; engagement of valve 152 relieves increased pressure in one of the first portion 140a and the second portion 140b, lessening the applied hydraulic pressure. [0006] The position of each plunger 160 within each bore 170a, 170b must be reset when axle stop settings or tire sizes of the vehicle are changed. To re-position the plunger 160 in the known power steering system 100, a user drives a punch into the bore 170a, 170b from an area exterior of the power steering system 100, the punch moving the plunger 160 further into the chamber 140. The progression of vehicle technology increasingly requires electronic

components to be incorporated within existing vehicle systems. To incorporate electronic components into the known power steering system 100, components related to the input steering shaft 110 must be positioned within the bearing cap 120 at the location of the bore 170a. The known power steering system 100 consequently cannot accommodate required electronic components while permitting resetting of the plunger 160 position.

SUMMARY

[0007] A plunger assembly for a power steering system comprises a plunger and a tappet.

The plunger is disposed within and longitudinally movable along a plunger passageway in a housing of the power steering system. The tappet is disposed within and longitudinally movable along a port in the housing. The port is disposed at an angle with respect to the plunger passageway within the housing. The port communicates with the plunger passageway and an area exterior of the power steering system.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The invention will now be described by way of example with reference to the accompanying figures, of which:

[0009] Figure 1 is a sectional view of a known power steering system;

[0010] Figure 2 is a sectional view of the power steering system according to the invention;

[0011] Figure 3 is a detailed sectional view of a plunger assembly of the power steering system of Figure 2 in an axle stop position;

[0012] Figure 4 is a detailed sectional view of the plunger assembly of Figure 3 in an extended position; and

[0013] Figure 5 is a detailed sectional view of the plunger assembly of Figure 3 in a compressed position. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0014] Exemplary embodiments of the present invention will be described hereinafter in detail with reference to the attached drawings, wherein like reference numerals refer to like elements. The present invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that the present disclosure will be thorough and complete, and will fully convey the concept of the disclosure to those skilled in the art.

[0015] A power steering system 1 according to the invention is shown in Figure 2. The power steering system 1 includes a housing 10, a piston 20, a steering shaft 30, a plurality of electronic components 40, and a plunger assembly 50. The major components of the invention will now be described in greater detail.

[0016] The housing 10, as shown in Figure 2, includes a chamber body 12 and a bearing cap 14 attached to the chamber body 12 to define a chamber 16. The chamber 16 contains a hydraulic fluid.

[0017] The chamber body 12, as shown in Figure 2, has a substantially enclosed first end

122 and an open second end 124. A bore 126 of the chamber body 12 extends horizontally through the first end 122, communicating between the chamber 16 and an area exterior of the housing 10.

[0018] The bearing cap 14, as shown in Figures 2 and 3, has a plunger passageway 142, a port 144, and a stop 146.

[0019] The plunger passageway 142, as shown in Figures 2 and 3, extends horizontally from a first side 14a of the bearing cap 14 adjacent the chamber 16 and into the bearing cap 14. The plunger passageway 142 extends partially into the bearing cap 14 and does not extend fully through the bearing cap 14.

[0020] The port 144, as shown in Figures 2 and 3, is disposed at an angle with respect to the plunger passageway 142 and communicates with the plunger passageway 142 and an area exterior of the housing 10 at a second side 14b of the bearing cap 14. The port 144 has a first port section 144a and second port section 144b. The first port section 144a communicates with the plunger passageway 142 and the second port section 144b communicates with the area exterior of the housing 10. As shown in Figure 3, a diameter of the first port section 144a is smaller than a diameter of the second port section 144b. In an embodiment, the second port section 144b is threaded.

[0021] The stop 146, as shown in Figures 2 and 3, is a protrusion of the bearing cap 14 extending into the port 144 and is disposed at an end of the first port section 144a connected to the plunger passageway 142.

[0022] The piston 20, as shown in Figure 2, is a cylindrical member disposed in the chamber 16. The piston 20 may be a known piston used in hydraulic power steering systems.

[0023] The steering shaft 30, as shown in Figure 2, is an elongated member extending through the bearing cap 14 and into the chamber 16. The steering shaft 30 is rotatably held by the bearing cap 14. The steering shaft 30 may be a known steering shaft used in hydraulic power steering systems.

[0024] The plurality of electronic components 40 are shown in Figures 2 and 3. The electronic components 40 may be any type of electronic component used in a power steering system including sensors and controllers related, for example, to steering input via the steering shaft 30, the hydraulic fluid in the chamber 16, movement of the piston 12, or any other aspects of the power steering system 1. In the shown embodiment, the electronic components 40 are disposed within the bearing cap 14 concentrically around the steering shaft 30. A portion of the electronic components 40 is disposed adjacent an end of the plunger passageway 142 and above the port 144 in a vertical direction extending transverse to the steering shaft 30.

[0025] The plunger assembly 50, as shown in Figures 2 and 3, includes a plunger 52, a tappet 54, a hollow-lock set screw 56, and a port plug 58.

[0026] The plunger 52, as shown in Figure 3, includes a plunger body 522, a spring pin

524, and a nut 526. The plunger 52 may be a known type of plunger used in hydraulic power steering systems. The plunger body 522 is cylindrical and has a head 522a at a first end, a central portion 522b, and a protrusion 522c at an opposite second end. As shown in Figure 3, a diameter of the head 522a is greater than a diameter of the central portion 522b, and the diameter of the central portion 522 is greater than a diameter of the protrusion 522c. The spring pin 524 is formed of a rolled sheet of resilient material and is disposed circumferentially around the central portion 522. The nut 526 is disposed on the central portion 522b adjacent the protrusion 522c; in an embodiment, the nut 526 has threads engaging complementary threads on the central portion 522b, but one with ordinary skill in the art would understand that other fasteners could be used to attach the nut 526 to the central portion 522c. The spring pin 524 is disposed between and abuts both the head 522a and the nut 526. The protrusion 522c, as shown in Figures 3-5, protrudes beyond the nut 526 in a longitudinal direction of the plunger 52.

[0027] The tappet 54, as shown in Figure 3, includes a tappet body 542 and a tappet O- ring 544. The tappet body 542 is a cylindrical member having a first end 542a and an opposite second end 542b. The tappet O-ring 544 is disposed circumferentially around the tappet body 542 adjacent the first end 542. The tappet O-ring 544 is formed of a resilient material such as rubber and may be any type of O-ring known to those with ordinary skill in the art.

[0028] The hollow-lock set screw 56, as shown in Figure 3, is an annular member having outer threads 562 disposed along an outer circumference and a punch receiving passageway 564 extending through a center of the hollow-lock set screw 56.

[0029] The port plug 58, as shown in Figure 3, has a plug body 582, a flange 584 disposed on an end of the plug body 582, and a port O-ring 586. The port plug 58 is formed from a metal material such as steel. In the shown embodiment, an outer surface of the plug body 582 is threaded. The port O-ring 586 is formed of a resilient material such as rubber and may be any type of O-ring known to those with ordinary skill in the art.

[0030] The assembly of the power steering system 1 will now be described in greater detail with reference to Figures 2 and 3.

[0031] The plunger 52 is assembled with the nut 526 attached to the central portion 522b and the spring pin 524 held between the head 522a and the nut 526, as shown in Figure 3.

Before the chamber body 12 is attached to the bearing cap 14, the plunger 52 is inserted into the plunger passageway 142 from the first side 14a of the bearing cap 14. When inserted, an outer diameter of the plunger 52 at the spring pin 524 is slightly larger than an inner diameter of the bore 142; the spring pin 524 extends beyond outer edges of the head 522a. The spring pin 524 frictionally engages the plunger passageway 142. The plunger 52 is longitudinally movable along the plunger passageway 142, but any movement force is at least partially counteracted by the frictional forces. Another plunger 52 may be similarly inserted into the bore 126.

[0032] The tappet 54 is then inserted into the port 144 and is disposed in the first port section 144a, as shown in Figure 3. The tappet 54 has an outer diameter approximately equal to a diameter of the first port section 144a and is longitudinally movable along the first port section 144a. The tappet O-ring 544 maintains a seal with the first port section 144a as the tappet 54 moves along the first port section 144a. The hollow-lock set screw 56 is inserted into the port 144 after the tappet 54. The outer threads 562 of the hollow-lock set screw 56 engage the second port section 144b and the hollow-lock set screw 56 is inserted into the second port section 144b until it abuts an end of the first port section 144a. After the hollow-lock set screw 56 is inserted into the second port section 144b, the port plug 58 is inserted into the second port section 144b with the plug body 582 disposed in the second port section 144b and the flange 584 abutting the second side 14b of the bearing cap 14. The port O-ring 586 maintains a seal with the second port section 144b and, in the shown embodiment, the port plug 58 is held in the second port section 144b by threaded engagement.

[0033] As shown in Figure 2, the steering shaft 30 is inserted through the bearing cap 14 and the piston 20 is inserted into the chamber 16. The front side 14a of the bearing cap 14 is then attached to the second end 124 of the chamber body 12 and the steering shaft 30 engages the piston 20. In the fully assembled power steering system 1, as shown in Figures 2 and 3, the protrusion 522c of the plunger 52 extends into the chamber 16.

[0034] The function and method of setting the plunger 52 of the power steering system 1 will now be described in greater detail with reference to Figures 2-5. The plunger 52 is initially set using the plunger assembly 50, is positioned by the piston 20 during use of the power steering system 1, and can then be re-set using the plunger assembly 50.

[0035] The initial setting of the plunger 52 to an extended position E using the plunger assembly 50 will now be described with reference to Figure 4. The port plug 58 is first removed from the second port section 144b. The hollow-lock set screw 56 has an annular thickness which is greater than a difference between the diameter of the first port section 144a and the diameter of the second port section 144b; the tappet 54 can move along the first port section 144a but is stopped from entering the second port section 144b by the annular thickness of the hollow-lock set screw 56.

[0036] A punch 60, as shown in Figure 4, is inserted into the second side 14b of the bearing cap 14, through the second port section 144b, through the punch receiving passageway 564, and into the first port section 144a to contact the first end 542a of the tappet body 542. A user moves the punch 60 along a direction P, correspondingly moving the tappet 54 along the first port section 144a. The second end 542b of the tappet body 542 contacts the head 522a and remains in contact with the head 522a while the tappet 54 moves. Motion of the tappet 54 along the first port section 144a moves the plunger 52 along the plunger passageway 142 in a direction toward the first side 14a of the bearing cap 14 and the chamber 16. The tappet 54 is movable by the punch 60 along the first port section 144a until the second end 542b of the tappet body 542 abuts the stop 146.

[0037] The plunger 52 is in the extended position E shown in Figure 4 when the second end 542b of the tappet body 542 contacts the head 522a and the tappet 54 has been moved by the punch 60 such that the second end 542b also contacts the stop 146. In the extended position E, the protrusion 522c extends a furthest distance into the chamber 16. The punch 60 is removed and the port plug 58 is re-inserted into the second port section 144b once the plunger 52 is in the extended position E.

[0038] During use of the power steering system 1, the piston 20, shown in Figure 2, moves along the chamber 16 by rotational movement of the steering shaft 30 as a vehicle driver turns a steering wheel (not shown) connected to the steering shaft 30. Motion of the piston 20 is aided by asymmetric hydraulic pressure within the chamber 16 on each side of the piston 20.

[0039] To set a position of the plunger 52, with the plunger 52 in the extended position E and wheels of a vehicle having the power steering system 1 held off the ground, the vehicle driver turns the steering wheel connected to the steering shaft 30 until an axle (not shown) reaches an axle stop without hydraulic pressure. Motion of the steering shaft 30 moves the piston 20 along the chamber 16, and the piston 20 engages the nut 526 and pushes the plunger 52 into the plunger passageway 142 until the axle reaches the axle stop. Motion of the plunger 52 into the plunger passageway 142 also moves the tappet 54 along the first port section 144a but the tappet 54 is held in the first port section 144a by the hollow-lock set screw 56.

[0040] When the axle reaches the axle stop, the piston 20 positions the plunger 52 at an axle stop position A in the plunger passageway 142 shown in Figure 3. For every subsequent movement of the piston 20, with the wheels of the vehicle on the ground and the hydraulic pressure within the chamber 16 applied, the plunger 52 remains in the axle stop position A and the piston 20 reaches an end of travel at which a valve of the piston 20 only engages the protrusion 522c. The protrusion 522c engages the piston 20 to relieve the hydraulic pressure within the chamber 16 and prevent the axle from reaching the axle stop, and correspondingly, the piston 20 from reaching the nut 526, under hydraulic pressure. [0041] The axle stop position A is a position between the extended position E shown in

Figure 4 and a compressed position C of the plunger 52 shown in Figure 5. In the compressed position C, the nut 526 abuts the plunger passageway 142 adjacent the first side 14a of the bearing cap 14 and the protrusion 522c extends a shortest distance into the chamber 16. The precise position of the axle stop position A between the compressed position C and the extended position E depends on axle stop settings and tire sizes of a vehicle incorporating the power steering system 1. The axle stop position A may be co-located with the extended position E or the compressed position C.

[0042] The axle stop position A of the plunger 52 within the plunger passageway 142 must be reset when axle stop settings or tire sizes of the vehicle are changed. To reset the plunger 52, the port plug 58 is removed from the second port section 144b and the punch 60 is used to move the plunger 52 to the extended position E as described above. The port plug 58 is replaced and the piston 20 then moves the plunger 52 to a new axle stop position A during use of the power steering system 1.

[0043] Advantageously, in the power steering system 1 having the plunger assembly 50 according to the invention, the positioning of the port 144 with respect to the plunger passageway 142 and the use of the tappet 54 permit the plunger 52 to be reset to the extended position E even when electronic components 40 prevent the plunger passageway 142 from extending fully through the bearing cap 14 in the horizontal direction. The use of the tappet 54 also prevents the punch 60 from directly contacting the plunger 52, avoiding damage and potential impairment of plunger 52 function. Additionally, the stop 146 limits the motion of the tappet 54 and prevents the tappet 54 from contacting an edge of the plunger passageway 142, further avoiding damage and potential impairment of plunger 52 function.