Summer Training Report

On
Sona Koyo Steering
Systems Ltd.

Company Profile:Sona Koyo Steering Systems Ltd. (hereafter Sona-Koyo)

was founded in 1985 as Sona Steering Systems Ltd. The first
manufacturing plant is situated in the city of Gurgaon about 35 Km
from New Delhi, the capital of India. The company entered into
technical collaboration agreement with JTEKT Corporation formally
called as Koyo Seiko Co., Ltd. Japan (hereafter JTEKT) for the
manufacture of Manual Steering Gear assemblies and Steering
Column assemblies. Maruti Suzuki India limited, the largest car
manufacturer in the country picked up 10% equity giving Sona-Koyo
the status of a Joint Venture Company
Due to customer demand, Sona-Koyo started
manufacturing driveline products like Propeller shafts and Axle
assemblies in 1990 ~1993. Sona-Koyo started manufacturing and
selling Hydraulic Power Steering assemblies and Energy Absorbing
Steering Columns as the demand for these started in India. In order to
meet the requirement of customers in south India, the company
established a plant about 45 kilometers from Chennai in 1998. Due to
increased customer demand, the company established a plant at
Dharuhera, about 35 kilometers from Sona Koyo Steering System Ltd.,
Gurgaon, in 2007.

Core values
Respect for the Individual
Service to the Customer
Excellence in pursuit of our goals

Recent Awards for Sona Koyo

TERI Corporate Environmental Excellence Award 2007*

TPM Excellence Award in 2007

Hyundai 2009
Best Co-operative Vendor

Maruti Suzuki 2010 & 2011

Improvement in Warranty Returns (2010)
Research & Development (2011)
Overall Excellence (GOLD) (2010)

Tier 2 Up-gradation (2010 & 2011)

Toyota 2010
Quality Certificate

EZ-Go 2010
Best Award for Quality < 2 PPM

Sona Customers India

Sona Customers global

Manufacturing Locations

Sona Koyo I -Gurgaon

Sona Koyo III-Dharuhera

DHARUHERA
GURGAON

Sona Koyo
Sanand, Gujarat

CHENNAI

Sona Koyo II Chennai(DOM +

EOU

PRODUCT AWARENESS

Technology & Products

Steering Systems
STEERING GEAR

STEERING COLUMN

Rack and Pinion Manual Steering

Column - Rigid

Rack and Pinion Power Steering

Column Collapsible

R.B.S. Manual Gear Assembly

Column Collapsible & Tilting

Column- Telescoping and Tilt
Column- Intermediate Shafts
Electric Power Steering (CEPS)

Drive Line
Case Differential Assembly

Rear Axle Assembly

Cut Bevel Gears

Propeller Shaft

Steering Gear
New !

R&P Manual

R&P Power

(Integrated Housing)

R&P Manual
RBS Manual

Steering Columns
Collapsible
& Tilt

Collapsible

Telescoping & Tilt

Collapsible
& Tilt

Rigid

New !

Intermediate Shafts
New !

Intermediate Shaft

Lateral Impact Energy Absorption

Axial Impact Energy Absorption

Vibration Absorption
Axial Impact Energy Absorption

Intermediate Shaft
Intermediate Shaft

Intermediate Shaft
Intermediate Shaft

Case Differentials

F8D & F10D

Versa

Zen & Esteem

Indica

Omni

Indigo

CUSTOMER SEGMENTS

Economy Cars

Tractors

Premium Cars

MUV

LCV
LCV Light Commercial Vehicle

STEERING SYSTEM
General
There are two basic types of steering system on commercial
vehicles : manual and power. In the manual system, the
drivers effort to turn the steering wheel is the primary force
that causes the front wheels to turn to the left or right on the
steering knuckles. With power steering, the drivers turning
efforts are multiplied by a hydraulic assist.
The manual steering system incorporates a steering wheel,
shaft, column, a manual gear box and pitman arm; drag link
and knuckle arm, tie rod.
The power steering system adds a hydraulic pump; fluid
reservoir, hoses, lines; and either a power assist unit mounted
on, or integral with, a power steering gear assembly.
For driver protection, all steering columns and shafts are
designed and constructed to collapse and/or deform in the

STEERING SYSTEM
Manual Steering Gears and Linkage
Dust Boot
Rack Bushing
Steering Pinion
Inner Tie Rod

Tie Rod Lock Nut

Steering Rack

[Rack & Pinion Type]

STEERING SYSTEM
Manual Steering Gears and Linkage
There are several different manual steering gears in current and recent
use. The rack-and-pinion type is the current choice of most
manufacturers for passenger vehicle. A typical manual rack-and-pinion
steering gear assembly consists of a pinion shaft and bearing assembly,
rack gear, gear housing, two tie rod assemblies, an adjuster assembly,
dust boots and boot clamps, and mounting grommets and bolts.
When the steering wheel is turned, this manual movement is relayed to
the steering shaft and shaft joint, then to the pinion shaft. Since the
pinion teeth mesh with the teeth on the rack gear, the rotary motion is
changed to transverse movement of the rack gear. Then, the tie rods
and tie rod ends transmit this movement to the steering knuckles and
wheels.

Sona

STEERING SYSTEM
Manual Steering Gears and Linkage
Worm
Shaft

Return
Tube
Ball
Bearing

Sector Shaft
Ball Nut
Main Shaft

Ball
Nut

Sector
gear

Ball Tubes
Balls
Housing

[Ball & Nut Type]

STEERING SYSTEM
The re-circulating ball type is a past favorite because the balls
Manual Steering Gears and Linkage
act as a rolling thread between the worm gear and the ball nut. It
is used in most commercial vehicles steering system. With this
steering gear, turning forces are transmitted through ball
bearings from a worm gear on the steering shaft to a sector gear
on the cross shaft.
A ball nut assembly is filled with ball bearings which roll along
tubes between the worm teeth and grooves inside the ball nut.
When the steering wheel is turned, the worm gear on the end of the
steering shaft rotates, and movement of the re-circulating balls
causes the ball nut to move up-and-down along the worm.
Movement of the ball nut is carried to the sector gear by teeth on
the side of the ball nut. The sector gear, in turn, moves with the
ball nut to rotate the cross shaft and activate the steering linkage.
The balls re-circulate from one end of the ball nut to the other
through ball return guides.

STEERING SYSTEM
Power Steering System (Ball & Nut
type)
Steering Wheel

Steering Column
Ball & Nut Gear

Pitman Arm

Drag Link

Tie Rod

Power Steering Pump

STEERING SYSTEM

Steering Gears and Linkage

Steering Wheel
Steering Column

Power Steering Pump

Power Steering Gear Box
(Rack & Pinion)

STEERING SYSTEM

Power Steering System

Over the year, power steering has become a standard equipment item
on many larger domestic models. With that and the optional demand for
this system, power steering is installed on over 90 percent of all
domestic new car production. Most late-model cars with power steering
use either a power rack-and-pinion system or an integral power
steering gear assembly. Generally, the rack-and-pinion system is
installed on front wheel drive cars. The integral power steering gear is
used on many rear-wheel drive cars.
All systems require a power steering pump attached to the engine and
driven by a belt, a pressure hose assembly, and a return line. Also, a
control valve is incorporated somewhere in the hydraulic circuit.
Automobile power steering is actually power-assisted steering. All
systems are constructed so that the car can be steered manually when
the engine is not running or if any failure occurs at the power source.

STEERING SYSTEM

Steering Gears Mounting condition

Pump

Reservoir

Hoses

Hydraulic
Steering
Gear

Column

STEERING SYSTEM
Power Steering System (Rack & Pinion type)
Torsion Bar

Right Turn
Oil Flow

Left Turn
Oil Flow

In
Out
Left Turn
Right Turn

COLUMN ASSY.

Serration
Upper bkt.

Upper jkt

Brg.

Lower bkt
Upper shaft
I/shaft

Capsule
Lower jkt

Upper U.J
Bush

Lower U.J

C-EPS.

( Column Electric Power Steering)

Steering System in Which Electronics
Controlled Motor is used to Provide
Assistance to the Driver.

ECU R&D

Collapse Mechanism

Motor

Actuation Mechanism

ECU R&D

ECU

WHY EPS ?
Less Fuel Consumption(0.5% against 3% in
HPS)
Retunability of Steering Feel

ECU R&D

Modularity Quick Assembly

Compact Size
Environmental Friendliness
Low Cost (save $5 to $10 per Car)
Design Flexibility
ECU R&D

ECU

Rear Axle Assy.

Break Drum

Axle
shaft

Differential
Thread in
parking cable

Differential Assy.
Crown Wheel

Case assy
Carrier

Sun gear

Pinion shaft
Pinion gear

FUNCTION OF Differential

<
Turning angle

Gears & Case Differential

Case Differential

Differential Ring
Hole

Spherical
washer

Shim

PROPELLER SHAFT ASSY.

Flange Yoke

P/shaft tube

Slide Yoke

The p/shaft transmits the power from gear box to rear axle with the help of
U.J . Universal joint are fitted on both the ends of the shaft.
The p/shaft has to operate at varied lengths and angles. To adjust
angular motion ,U.J are provided. To adjust for the change in length is
p/shaft, a slip joint is provided.

Spider

N/Brg.

Yoke
A Universal joint couples two shafts (i.e driven & driving) that permits drive
shaft to transmit power to driven shaft at an angle.
Need: It is needed because the rear end of the propeller shaft is constantly
rising and falling due to
a)

The flexing of the chassis springs due bumpy road.

b)

They also allow to rear axle assy, to twist due to the drive and brake
torque reaction.

Thank
You