Electronic Power Steering Endurance Test Bench

The EPS Endurance Test Bench simulates real-world driving conditions to evaluate the durability of electronic power steering systems. It utilizes electric actuators to apply rotational and axial forces, with testers for both driver input and load condition simulations.

Solution Description

The endurance test bench is designed to evaluate the durability and strength of components within an electronic power steering (EPS) system.

The machine simulates real-world driving conditions by using electric actuators to apply rotational and axial forces to the steering system.

It includes two primary testers: one for rotational input (mimicking driver input) and another for combined rotational and axial displacement (simulating load conditions).

Technology Stack

EtherCAT, CANopen, Modbus, EtherNet/IP, DeviceNET, Profi-Net, and Profi-bus for real-time data exchange and control.

Firmware for precise control and monitoring of the testing equipment.

A desktop application compatible with Linux RT (real-time) environments, providing a versatile interface for test setup and data analysis.

Kikusui power supply control.

Outcome and Benefits Delivered:

Enhanced product reliability by identifying potential weaknesses in the EPS system before mass production.

Reduced warranty claims and improved customer satisfaction by ensuring that the steering components meet durability standards.

The ability to simulate long-term usage scenarios, helping manufacturers optimise design and material choices for better performance.

The Business Context and Challenges of the Customer:

The customer is an automotive parts manufacturer facing increased demand for more reliable and efficient electronic power steering systems.

There was a need to validate the longevity and performance of the EPS components under various operating conditions, as failures in the field could lead to costly recalls and damage to brand reputation.

The challenge was to create a versatile and accurate testing solution that could handle a wide range of test scenarios, reflecting real-world conditions.

System Overview:

The system consists of a mechanical test bench controlled by a desktop application in a Lynx environment, providing precise control over the test parameters and real-time data collection.

The block diagram should illustrate the interaction between the rotational input tester, the combined rotational and axial displacement tester, and the control system.

Mechanical Test Bench:

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Composed of high-precision electric actuators capable of applying specific forces and movements to the EPS system.
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The bench is designed to accommodate different EPS models, allowing for flexibility in testing various configurations.

Desktop App in Lynx Environment:

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The Lynx-based desktop application provides an intuitive interface for setting up tests, controlling actuators, and monitoring test progress.
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It includes features for real-time data acquisition, analysis, and reporting, enabling quick identification of any issues during testing.