Description:Complete Specification:
The following specification describes and ascertains the nature of this invention and the manner in which it is to be performed.

Field of the invention:
[0001] The present invention relates to a steering corner module for a vehicle.

Background of the invention:
[0002] In conventional steering system, rack is connected to the wheels with tie rods to achieve the required steering angle where it has the complex mechanical structure. The input is received from steering wheel to sensor unit via torsion bar then signal sent to ECU, accordingly then motor produces the torque and transmits to steering rack by servo unit and the drive pinion assembly. The torque transmission ratio is completely controlled by the gear ratio of various drive units. In the conventional steering system, the motor is directly coupled to the worm shaft and an output torque of the motor is transmitted to the steering rack by worm shaft and the drive pinion assembly. The torque transmission ratio is controlled by the gear ratio of the worm and drive pinion.

[0003] According to a patent literature WO06117344, a steering device, in particular for a rear axle steering system is disclosed. A steering device is characterised by a wheel-guiding member whose length can be adjusted by means of an electromotor, a gear arranged on the wheel-guiding member causing the length of the wheel-guiding member to change as a result of rotation of a drive shaft of the electromotor, thus leading to a change in the wheel steering lock angle. The electromotor is fastened to the car body, and a drive shaft of the electromotor is connected to the gear by a transmission element.

Brief description of the accompanying drawings:
[0004] An embodiment of the disclosure is described with reference to the following accompanying drawings,
[0005] Fig. 1 illustrates a steering corner module with a first configuration, according to an embodiment of the present invention;
[0006] Fig. 2 illustrates the steering corner module with a second configuration, according to an embodiment of the present invention, and
[0007] Fig. 3 illustrates the steering corner module with the first configuration having different gear unit, according to an embodiment of the present invention.

Detailed description of the embodiments:
[0008] Fig. 1 illustrates a steering corner module with a first configuration, according to an embodiment of the present invention. The steering corner module 100 is operable by a Steer-by-Wire (SbW) system (not shown) of the vehicle. The steering corner module 100 comprises an actuator comprising a motor 104 with a rotor shaft 308 (shown in Fig. 3). The actuator is couplable to a steering knuckle 114 (or stub axle) of a wheel 116 of the vehicle, to provide steering control of the wheel 116, characterized in that, the actuator, and the steering knuckle 114 are coupled with each other through an assembly unit 120.

[0009] According to an embodiment of the present invention, the assembly unit 120 comprises a flexible shaft 110 coupling the rotor shaft 308 of the motor 104 and the steering knuckle 114. The at least one of the rotor shaft 308 and the steering knuckle 114 are coupled with a gear assembly 106, 202, 310 before coupling through the flexible shaft 110. The gear assembly 106, 202, 310 is possible to any combination of known gears in the art however only few of those are explained for clarity and understanding.

[0010] According to an embodiment of the present invention, a first configuration of the assembly unit 120 of the steering corner module 100 is disclosed. In the first configuration, the flexible shaft 110 is directly coupled to the steering knuckle 114 and coupled to the rotor shaft 308 through a first gear unit 106. The motor 104 is mounted to the chassis 108 (sub-frames) or to the wheel assembly, either directly or through a bracket, of the vehicle and coupled to the first gear unit 106. An output end of the first gear unit 106 is coupled to the steering knuckle 114 through the flexible shaft 110. The chassis 108 is also mounted to the steering knuckle 114 through a lower frame 112. The flexible shaft 110 is coupled to the steering knuckle 114 through a collar or coupler 118. The flexile shaft 110 is routable through any direction thus providing technical advancement of positioning the steering corner module 100. The steering knuckle 114 also supports a MacPherson strut 122 to the vehicle chassis 108.

[0011] According to the present invention, the flexible shaft 110, is also referred to as a Bowden cable or wire rope. The flexible shaft 110 transmits rotary motion much like a solid steel shaft, but is capable to be routed over, under, and around obstacles that would make using a solid shaft impractical. The assembly of flexible shaft 110 consists of a rotating shaft (sometimes called a core) with end fittings for attachment to the driving and driven mating parts. A protective outer casing is used when necessary. This casing has its own fittings, called ferrules, which keep it stationary during use. The flexible shaft 110 is a highly effective means of transmitting rotary motion and is more efficient than universal joints, gears, sprockets and chains, or belts and pulleys. The flexible shafts 110 can be used for bi-direction rotation application.

[0012] According to an embodiment of the present invention, the steering corner module 100 operable by the Steer-by-Wire (SbW) system of the vehicle is provided. The steering corner module 100 comprises a wheel assembly, and the actuator comprising the motor 104 with a rotor shaft 308 (shown in Fig. 3). The actuator is couplable to the steering knuckle 114 (or stub axle) of the wheel assembly of the vehicle, to provide steering control of the wheel 116, characterized in that, the actuator, and the steering knuckle 114 are coupled with each other through an assembly unit 120.

[0013] According to an embodiment of the present invention, a steering assembly for a steering corner module 100 is provided. The steering corner module 100 is operable by the Steer-by-Wire (SbW) system of the vehicle. The steering corner module 100 comprises a wheel assembly, and the actuator comprising the motor 104 with a rotor shaft 308 (shown in Fig. 3). The actuator is couplable to the steering knuckle 114 (or stub axle) of the wheel assembly of the vehicle, to provide steering control of the wheel 116, characterized in that, the steering assembly comprises coupling the actuator, and the steering knuckle 114 with each other through the flexible shaft 110.

[0014] According to an embodiment of the present invention, the steering corner module 100 is independent steering module which is provided for each wheel 116 of the vehicle. The steering corner module 100 itself comprises the wheels 116 which is made available for the vehicle, or only the combination of motor 114 and the coupling to the steering knuckle 114 is provided to make the existing wheels 116 of the vehicle individual steering. The existing steering setup of the conventional steering system is removed.

[0015] According to the present invention, the steering corner module 100 as described is a standalone unit comprising steering control and braking control. In addition, the steering corner module 100 is possible to be provided with traction motor as well.

[0016] Fig. 2 illustrates the steering corner module with a second configuration, according to an embodiment of the present invention. In the second configuration, the flexible shaft 110 is directly coupled to the rotor shaft 308 of the motor 104 and coupled to the steering knuckle 114 through a second gear unit 202. The second configuration is similar to the first configuration with the modification being that the coupling and the gear unit are interchanged. Specifically, the second gear unit 202 is coupled to the steering knuckle 114, to which the flexible shaft 110 is coupled. The other end of the flexible shaft 110 is connected to the rotor shaft 308 of the motor 104 through direct coupling using collar 118. Further, the second gear unit 202 is mounted to a pivot point of the steering knuckle 114. Also, the direct coupling is enabled through the collar 118.

[0017] According to the Fig. 1 and Fig. 2, the first gear unit 106 and the second gear unit 202 comprises at least one of a worm gear assembly and a spur gear assembly 310. The worm gear assembly comprises a worm shaft coupled to the rotor shaft 308 which is splined with the worm gear. The worm gear is then coupled with the flexible shaft 110. The worm gear is coupled to the rotor shaft 308 through coupler as known in the art. The worm shaft and worm gear is provided as an example and the present invention is not limited to the same.

[0018] According to an embodiment of the present invention, the steering corner module 100 is provided with a third configuration of the assembly unit 120. In the third configuration of the assembly unit 120, the flexible shaft 110 is coupled to the rotor shaft 308 through the first gear unit 106 and coupled to the steering knuckle 114 through the second gear unit 202.

[0019] Fig. 3 illustrates the steering corner module with the first configuration having different gear unit, according to an embodiment of the present invention. In the first configuration with different gear unit, the rotor shaft 308 of the motor 104 is mounted with a first spur gear 302, which is in engagement with a second spur gear 304. The second spur gear 304 is mounted on an output shaft 306. An end of the output shaft 306 is coupled with the flexible shaft 110, which in turn is coupled to the steering knuckle 114.

[0020] According to an embodiment of the present invention, the gear assembly 106, 202, 310 is selectable from any one of the worm gear coupled with the worm wheel, and the spur gear assembly 310 coupled with the output shaft 306. Thus in the first configuration, the spur gear assembly 310 is also possible to be used instead of the worm gear assembly. Similarly, in the second configuration, the spur gear assembly 310 is usable in place of the worm gear assembly. Similarly, in the third configuration, the first gear unit 106 and the second gear unit 202 are usable to be any combination of the worm gear assembly and the spur gear assembly 310.

[0021] According to an embodiment of the present invention a working (or mounting arrangement) of the steering corner module 100 is provided. The steering corner module 100 comprises the flexible shaft 110, the servo unit assembly which includes motor 104, gear assembly and an Electronic Control Unit (ECU) 102. In addition to that, the flexible shaft 110 and gear assembly 106, 202, 310 is used in combination with vehicle suspension unit and wheels 116.

[0022] According to an embodiment of the present invention, a mounting arrangement and working of the first configuration is explained. The motor 104 (or servo unit assembly) is fitted into the vehicle subframe, and the flexible shaft 110 couples the steering knuckle 114 and the motor 104. The first gear unit 106 is either coupled to the rotor shaft 308 of the motor 104. The ECU 102 (which is fitted on the servo unit or motor 104) is configured to receive the signals from the SbW unit or Vehicle Control Unit (VCU). The ECU 102 transmits the signals to the motor 104, and the motor 104 generates the torque which is coupled with the first gear unit 106 which comprises the worm shaft and worm wheel. The output from the worm wheel is transmitted to flexible shaft 110. The steering force from flexible shaft 110 is transferred to the steering knuckle 114 which is used to translate the rotational movement of the wheel 116 with respect to the suspension axis / King pin axis.

[0023] According to the present invention, the mounting and working of the second configuration is explained. The motor 104 with the ECU 102 is fit into the vehicle subframe, and the flexible shaft 110 connects/couples the motor 104 to the second gear unit 202 which has been connected directly to the wheel hub or steering knuckle 114. The ECU 102 receives the signals from the SbW unit or the VCU. The ECU 102 gives the signals to the motor 104, and torque is generated. The motor 104 is directly coupled with flexible shaft 110 other end of the flexible shaft 110 connected with second gear unit 202. The steering force from the flexible shaft 110 is transferred to second gear unit 202 where the torque is multiplied which is used to translate the rotational movement of the wheel 116 with respect to the suspension axis / King pin axis.

[0024] According to the present invention, the mounting and working of the first configuration with different gear unit is explained. The motor 104 with ECU 102 is fit into the vehicle subframe and the spur gear assembly 310 is coupled with the output shaft 306. The flexible shaft 110 is coupled between output shaft 306 and the second gear unit 202 which has been connected directly to the wheel hub. As similar to previous configurations, the ECU 102 receive the signals from the SbW unit or VCU. The ECU 102 gives the signals to the motor 104, and the motor 104 generates the torque. The motor 104 is directly coupled with different gear unit having spur gears in engagement with output shaft 306 (or splined shaft). The rotational movement of output shaft 306 is transmitted to the different gear unit through flexible shaft 110. The second gear unit 202 is fixed on to the steering knuckle 114 and provide rotational movement with respect to the suspension axis / King pin axis.

[0025] In accordance to an embodiment of the present invention, the ECU 102 is provided with necessary signal detection, acquisition, and processing circuits. The ECU 102 is the one which comprises input interface, output interfaces having pins or ports, the memory element such as Random Access Memory (RAM) and/or Read Only Memory (ROM), Analog-to-Digital Converter (ADC) and a Digital-to-Analog Convertor (DAC), clocks, timers, counters and at least one processor (capable of implementing machine learning) connected with each other and to other components through communication bus channels. The memory element (not shown) is pre-stored with logics or instructions or programs or applications or modules/models and/or threshold values/ranges, reference values, predefined/predetermined criteria/conditions, lists, knowledge sources which is/are accessed by the at least one processor as per the defined routines. The internal components of the ECU 102 are not explained for being state of the art, and the same must not be understood in a limiting manner. The ECU 102 may also comprise communication units such as transceivers to communicate through wireless or wired means such as Global System for Mobile Communications (GSM), 3G, 4G, 5G, Wi-Fi, Bluetooth, Ethernet, serial networks, and the like. The ECU 102 is implementable in the form of System-in-Package (SiP) or System-on-Chip (SOC) or any other known types. Examples of ECU 102 comprises but not limited to, microcontroller, microprocessor, microcomputer, etc.

[0026] Further, the processor may be implemented as any or a combination of one or more microchips or integrated circuits interconnected using a parent board, hardwired logic, software stored in the memory element and executed by a microprocessor, firmware, an application specific integrated circuit (ASIC), and/or a field programmable gate array (FPGA). The processor is configured to exchange and manage the processing of various Artificial Intelligence (AI) modules.

[0027] According to the present invention, the steering corner module 100 with flexible shaft 110 is provided. The steering corner module 100 is retrofittable to existing vehicle and implementable for new vehicles. The steering corner module 100 is mountable to existing chassis 108 and steering knuckles 114 of the existing vehicle or a housing/structure of the steering corner module 100 itself. The steering corner module 100 with flexible shaft 110 is compact steering system includes electric drive (or motor 104) and flexible shaft 110 aims to use it in the next generation vehicles such as individual wheel drive vehicles. The steering corner module 100 is adaptable for the existing system. The present invention enables possibility of high flexibility on steering angles and enables managing of higher loads due to independent wheels 116 with less mechanical components. The present invention also provides a required torque to turn the tyres independently with compact steering corner module 100 with flexible shaft 110. The steering corner module 100 of the present invention comprise of the flexible shaft 110 and electric motor 104 inbuilt on to each wheel 116. The central vehicle control unit provides the signal to steering motor 104 to produce the required torque which is transmitted into the wheels 116 by the flexible shaft 110 and reduction gear mechanism (or gear unit).

[0028] According to an embodiment of the present invention, the steering corner module 100 provides independent assist on each wheels 116, thereby helps to achieve different steering angles and easy maneuvering in complex parking situations. The present invention supports to drive the vehicle autonomously without any driver assistance replacing the existing conventional steering system. The steering corner module 100 is possible to be incorporated in the existing vehicles. Further, the steering corner module 100 is also adaptable to all type of suspension design. The steering corner module 100 utilizes less space and is compact on wheels 116 thus enables new interior concepts. The steering corner module 100 facilitates more agility through individual applicable driving dynamics and enhanced safety through the interaction of braking, sensing and steering system.

[0029] It should be understood that the embodiments explained in the description above are only illustrative and do not limit the scope of this invention. Many such embodiments and other modifications and changes in the embodiment explained in the description are envisaged. The scope of the invention is only limited by the scope of the claims.

, Claims:We claim:
1. A steering corner module (100) for a vehicle, said steering corner module (100) operable by a Steer-by-Wire (SbW) system of said vehicle, said steering corner module (100) comprises:
an actuator comprising a motor (104) with a rotor shaft (308), said actuator couplable to a steering knuckle (114) of a wheel (116) of said vehicle, to provide steering control of said wheel (116), characterized in that,
said actuator and said steering knuckle (114) are coupled with each other through an assembly unit (120).

2. The steering corner module (100) as claimed in claim 1, wherein said assembly unit (120) comprises a flexible shaft (110) coupling said rotor shaft (308) and said steering knuckle (114), and wherein at least one of said rotor shaft (308) and said steering knuckle (114) is coupled with a gear assembly (106, 202, 310) before coupling through said flexible shaft (110).

3. The steering corner module (100) as claimed in claim 2, wherein a first configuration of said assembly unit (120) comprises said flexible shaft (110) directly coupled to said steering knuckle (114) and coupled to said rotor shaft (308) through a first gear unit (106).

4. The steering corner module (100) as claimed in claim 2, wherein a second configuration of said assembly unit (120) comprises said flexible shaft (110) directly coupled to said rotor shaft (308) and coupled to said steering knuckle (114) through a second gear unit (202).

5. The steering corner module (100) as claimed in claim 4, wherein said second gear unit (202) is mounted to a pivot point of said steering knuckle (114).

6. The steering corner module (100) as claimed in claim 3 or claim 4, wherein said direct coupling is enabled through a collar (118).

7. The steering corner module (100) as claimed in claim 2, wherein said gear assembly is selectable from any one of a worm gear coupled with a worm wheel, and a spur gears coupled with an output shaft (306).

8. The steering corner module (100) as claimed in claim 2, wherein a third configuration of said assembly unit (120) comprises said flexible shaft (110) coupled to said rotor shaft (308) through a first gear unit (106) and coupled to said steering knuckle (114) through a second gear unit (202).

9. The steering corner module (100) as claimed in claim 1 is retrofittable to conventional vehicle.

10. The steering corner module (100) as claimed in claim 1, wherein said actuator is mountable to any one of said vehicle chassis (108) and a housing of said steering corner module (100).