Abstract:
A flexible rack for engagement with the gear of a drive system comprises two or more steel cords that are arranged parallel to one another in the longitudinal direction. The steel cords are surrounded by a polymer jacket wherein recesses are provided for engagement with the teeth of the drive gear. The centres of the steel cord are in a plane that is perpendicularly to a mirror plane of the cross section of the flexible rack. The two or more steel cords have equal numbers of left and right lay direction steel cords. Detailed embodiments have just two S and Z lay direction steel cords of equal construction. Preferred steel cords comprise filaments with second order helical deformation. The distance between the steel cords influences strongly the bending behaviour of the flexible rack and is between 0.80 to 2.5 times the diameter of the steel cord. In a drive system wherein the rack remains in a single plane the distance between the steel cords can be larger than in a drive system wherein bending out of a single plane is also required. The steel cords can be held together by one or more wraps.
Abstract:
A method of fabricating a rack, the method includes: supporting a first rack bar having a first toothed part on a shaft of the first rack bar; supporting a second rack bar having a second toothed part on a shaft of the second rack bar such that an axial center line of the second rack bar coincides with an axial center line of the first rack bar; supporting a joint member between the first and second rack bars such that an axial center line of the joint member coincides with the axial center lines of the first and second rack bars; rotating the joint member about the axial center lines of the first and second rack bars relative to the first and second rack bars; and bringing an end of the first rack bar and an end of the second rack bar into friction pressure welding with the joint member.