The present disclosure relates to a steering shaft for a motor vehicle, comprising an outer shaft which is configured as a hollow shaft and an inner shaft which is arranged coaxially in the hollow shaft. The inner shaft can be telescoped relative to the hollow shaft in the direction of the longitudinal axis of the steering shaft, and is connected to the hollow shaft in a torque-transmitting manner via at least one positively locking element. A securing apparatus with at least one stop element is attached on an end region of the hollow shaft which faces the inner shaft. A stop face is arranged in the opening cross section of the hollow shaft and faces the hollow shaft in the direction of the longitudinal axis.

A method of manufacturing a spline telescopic shaft includes a masking step in which, in a prescribed axial-direction region of an intermediate manufacturing product, partial tooth grooves that are equally spaced circumferentially are respectively covered by masking members that are equally spaced circumferentially; a resin coating step in which a resin layer is formed, and inner surfaces of the partial tooth grooves covered by the masking members are left as metal exposed portions that are equally spaced circumferentially; and a coating film forming step in which, in a state where the intermediate manufacturing product provided with the resin layer is centered with respect to a broach via the metal exposed portions, the intermediate manufacturing product and the broach are caused to slide relative to each other in an axial direction by press-fitting such that the resin layer is shaved to form a resin coating film.

A dust cap for a steering system is disclosed. A dust cap for a steering system, which has an accommodation hole for accommodating a pinion shaft and of which the lower part is coupled to a rack housing, according to an embodiment of the present invention comprises: a floor surface which extends from the upper part toward the outer side of the accommodation hole; a first rim forming a lateral wall on the edge of the floor surface; a second rim forming an intermediate wall between the first rim and the accommodation hole; and one or more slits insert-formed from the second rim toward the floor surface.

A dust cap for a steering system is disclosed. A dust cap for a steering system, which has an accommodation hole for accommodating a pinion shaft and of which the lower part is coupled to a rack housing, according to an embodiment of the present invention comprises: a floor surface which extends from the upper part toward the outer side of the accommodation hole; a first rim forming a lateral wall on the edge of the floor surface; a second rim forming an intermediate wall between the first rim and the accommodation hole; and one or more slits insert-formed from the second rim toward the floor surface.

A dust cover to cover an opening of a housing through which at least one of a shaft and a pipe extends includes a hole-edge portion and a main body. The at least one of the shaft and the pipe is extendable through the through hole. The hole-edge portion defines an edge of a through hole through which the at least one of the shaft and the pipe is extendable. The main body is configured to cover the opening. The main body has a hardness different from a hardness of the hole-edge portion.

To provide a method of manufacturing a shaft for a steering device, the shaft including a spline shaft part to be coupled with an input shaft, a stopper part to be coupled with an output shaft, and an intermediate shaft part that couples the spline shaft part with the stopper part. The method includes: a step of forming a hole part recessed in an axial direction from one end of a pillar-shaped material by forging; and a step of pressing the material in which the hole part has been formed into a die to perform drawing in a radial direction on a portion of the material at which the stopper part is formed and prolonging a length along the axial direction of the hole part at the same time by forging.

A cross shaft joint includes a cross shaft including four shaft parts, needle rollers rolling on outer peripheral faces of the shaft parts, bearing cups each having a cylindrical part, and a bottom part, and externally fitted to the shaft parts via the needle rollers, and yokes provided with bearing holes into which the bearing cups are inserted. The needle rollers are maintained in a tight fit state between the shaft parts and the bearing cups. Each cylindrical part is provided with a projected part projected radially inward of the cylindrical part in a curved shape, at an inner peripheral side thereof, and an apex of the projected part is in contact with the needle roller within a range in an axial direction of the needle roller, the range containing an axial center of the needle roller in the axial direction.

A cross shaft joint includes a cross shaft including four shaft parts, needle rollers rolling on outer peripheral faces of the shaft parts, bearing cups each having a cylindrical part, and a bottom part, and externally fitted to the shaft parts via the needle rollers, and yokes provided with bearing holes into which the bearing cups are inserted. The needle rollers are maintained in a tight fit state between the shaft parts and the bearing cups. Each cylindrical part is provided with a projected part projected radially inward of the cylindrical part in a curved shape, at an inner peripheral side thereof, and an apex of the projected part is in contact with the needle roller within a range in an axial direction of the needle roller, the range containing an axial center of the needle roller in the axial direction.

According to embodiments, it is possible to prevent vibration and gaps in a coupling structure between rotation shafts, thus allowing for reduction in noise, enhanced responsiveness, accurate steering, and a better straight driving performance.

An electric vehicle is provided. The vehicle includes a frame. A battery and a motor may be secured to the frame, such that the battery powers the motor which drives the vehicle. The vehicle may further include at least one axle including a plurality of wheels. A manual steering mechanism including a steering column is operable to pivot the wheels when the steering column is rotated. An overhead frame protrudes vertically from the main frame. A steering drive shaft is supported by the overhead frame and is operable to pivot the wheels when rotated. A head unit is secured to the steering drive shaft and includes a positive electrode and a negative electrode electrically wired to the battery. The head unit is operable to engage an overhead track. The overhead track transfers electrical power to the positive electrode and negative electrode, thereby recharging the battery and driving the motor while steering the electric vehicle.