1. Design and Prototype Build of the Interfaces of a Steer-By-Wire Assembly Javier Angulo
Alan Benedict, Team Leader
Amber Russell, Team Manager
Dr. Sohel Anwar, Faculty Advisor & Sponsor
Dr. Hazim El-Mounayri, Course Instructor
Create a steer-by-wire system parallel to that of an automobile for use in laboratory
4. Introduction (continued)
5. 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
6. Requirements and Targets Functionality and safety
Benchmark Visteon-GM Sequel
7. Requirements and Targets (continued)
8. Concept Development & Evaluation Development Process
Failure Mode Effects Analysis (FMEA)
9. Final Concept Motor to Rack-and-Pinion Interface
Motor to Motor Interface
Sensor to Sensor Interface
Stackable Sensors / Shaft
Sensor to Rack and Pinion Interface
10. 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
11. Product Generation & Evaluation Motor Interfaces
Allows for maintenance
12. 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)
13. 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
14. Product Generation & Evaluation Sensors
Ease of interface
Lack of availability
Requires less space
Meet accuracy requirement
Requires gear train interface (backlash)
15. Final Design
16. Final Design (continued)
17. Engineering Requirements
For further questions, please feel free to ask the design team or refer to the project report. Thank you.
19. 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.