Design and prototype build of the interfaces of a steer by wire assembly
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Design and Prototype Build of the Interfaces of a Steer-By-Wire Assembly. Javier Angulo Alan Benedict, Team Leader Amber Russell, Team Manager Kurush Savabi Dr. Sohel Anwar, Faculty Advisor & Sponsor Dr. Hazim El-Mounayri, Course Instructor. Overview. Purpose & Objective

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Design and prototype build of the interfaces of a steer by wire assembly l.jpg

Design and Prototype Build of the Interfaces of a Steer-By-Wire Assembly

Javier Angulo

Alan Benedict, Team Leader

Amber Russell, Team Manager

Kurush Savabi

Dr. Sohel Anwar, Faculty Advisor & Sponsor

Dr. Hazim El-Mounayri, Course Instructor


Overview l.jpg
Overview Steer-By-Wire Assembly

  • Purpose & Objective

  • Requirements & Targets

  • Concept Generation & Evaluation

  • Product Generation & Evaluation

  • Conclusions & Recommendations


Introduction l.jpg
Introduction Steer-By-Wire Assembly

Overall Purpose:

Create a steer-by-wire system parallel to that of an automobile for use in laboratory


Introduction continued l.jpg

Driver Interface Sub-System Steer-By-Wire Assembly

Microcontroller Sub-System

Rack-and-Pinion Sub-System

Introduction(continued)

Overall Steer-By-Wire System


Objectives of design l.jpg
Objectives of Design Steer-By-Wire Assembly

Objectives:

  • Design of an interface between a standard automotive rack-and-pinion steering assembly and electric motors.

  • Design of an interface between the same rack-and-pinion steering assembly and angle position sensors

  • Design of a stand to support the entire system and provide reaction forces to rack


Requirements and targets l.jpg
Requirements and Targets Steer-By-Wire Assembly

  • Functionality and safety

  • Benchmark Visteon-GM Sequel


Requirements and targets continued l.jpg
Requirements and Targets Steer-By-Wire Assembly(continued)


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Concept Development & Evaluation Steer-By-Wire Assembly

Development Process

  • Functional Decomposition

  • Function Concept-Mapping

    Evaluation Process

  • Feasibility Testing

  • Go/No-Go Screening

  • Decision Matrices

  • Failure Mode Effects Analysis (FMEA)


Final concept l.jpg
Final Concept Steer-By-Wire Assembly

  • Motor to Rack-and-Pinion Interface

    • Gear Train

  • Motor to Motor Interface

    • Gear Train

  • Sensor to Sensor Interface

    • Stackable Sensors / Shaft

  • Sensor to Rack and Pinion Interface

    • Direct Shaft

  • Metal Stand

Motor Controllers

Position Sensors

Motor

Motor

Stacked / Shaft

Rack

Pinion 1

Pinion 2

Gear Train


Product generation evaluation l.jpg
Product Generation & Evaluation Steer-By-Wire Assembly

Motors Requirements

  • Torque of 52 Nm at 67 rpm

  • Torque of 20.8 Nm at 133 rpm

  • Input voltage of <60 VDC

    Selected Motor Specifications

  • Torque of 52 Nm at 67 rpm

  • Torque of 20.8 Nm at 127.4 rpm

  • Input voltage of 75 VDC


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Product Generation & Evaluation Steer-By-Wire Assembly

Motor Interfaces

  • Enables redundancy

  • Allows for maintenance


Product generation evaluation12 l.jpg
Product Generation & Evaluation Steer-By-Wire Assembly

Stand Requirements

Max deflection of 12.7mm

Max stress of 450MPa

Stand Analysis Results

Max deflection of 1.83E-4mm

Max stress of 89.1MPa (Dynamic)

FOS 3 to 5 (267.3MPa to 445.5MPa)


Product generation evaluation13 l.jpg
Product Generation & Evaluation Steer-By-Wire Assembly

Springs

  • Spring Requirements of 102 kN/m

  • Selected Spring Specifications of 83 kN/m

  • Force of 6876 N (to simulate dynamic loading)

    • Maximum Stress = 104.6 MPa

    • Yield Strength of Plate = 250 MPa


Product generation evaluation14 l.jpg
Product Generation & Evaluation Steer-By-Wire Assembly

Sensors

Hollow-angle sensors

  • Ease of interface

  • Zero backlash

  • Lack of availability

  • Lower accuracy

  • Requires less space

    Conventional Potentiometers

  • Meet accuracy requirement

  • Readily available

  • Cost efficient

  • Requires gear train interface (backlash)


Final design l.jpg
Final Design Steer-By-Wire Assembly


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Final Design Steer-By-Wire Assembly (continued)


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Engineering Requirements Steer-By-Wire Assembly


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Questions Steer-By-Wire Assembly

For further questions, please feel free to ask the design team or refer to the project report. Thank you.


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References Steer-By-Wire Assembly

  • Cesiel, Daugherty, Gaunt, “Development of a Steer-by-Wire System for the GM Sequel”, SAE Technical Paper Series, 2006-01-1173.

  • David G. Ullman, “The mechanical design process”, Third edition, McGrawHill, 2003, USA.

  • “Delphi Non-Contact Multi-Turn Rotary Position Sensor”, Delphi, www.delphi.com.

  • “Electric Power Assisted Steering”, Visteon, 2005.

  • Matweb, www.matweb.com. March 2007.

  • Miller, Duane K., P.E., Use “Undermatching Weld Metal Where Advantageous: Practical Ideas for the Design Professional”, Welding Innovation, Vol. XIV, No. 1, 1997.

  • Parker Motion, www.parkermotion.com. April 2007.

  • Roy Mech, www.roymech.co.uk/useful_tables/form/weld_strength

  • “Sensors for Position Measurement: Single-turn/Multi-turn Steering-angle Sensor”, Hella International, www.hella.com.


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