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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

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
Overview
  • Purpose & Objective
  • Requirements & Targets
  • Concept Generation & Evaluation
  • Product Generation & Evaluation
  • Conclusions & Recommendations
introduction
Introduction

Overall Purpose:

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

introduction continued

Driver Interface Sub-System

Microcontroller Sub-System

Rack-and-Pinion Sub-System

Introduction(continued)

Overall Steer-By-Wire System

objectives of design
Objectives of Design

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
Requirements and Targets
  • Functionality and safety
  • Benchmark Visteon-GM Sequel
concept development evaluation
Concept Development & Evaluation

Development Process

  • Functional Decomposition
  • Function Concept-Mapping

Evaluation Process

  • Feasibility Testing
  • Go/No-Go Screening
  • Decision Matrices
  • Failure Mode Effects Analysis (FMEA)
final concept
Final Concept
  • 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
Product Generation & Evaluation

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
product generation evaluation11
Product Generation & Evaluation

Motor Interfaces

  • Enables redundancy
  • Allows for maintenance
product generation evaluation12
Product Generation & Evaluation

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
Product Generation & Evaluation

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
Product Generation & Evaluation

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)
questions
Questions

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

references
References
  • 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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