DESIGN OF A MODULAR STEERING SYSTEM TEST BENCH FOR DURABILITY,

PERFORMANCE AND CHARACTERIZATION TESTS

ELF KILIN, ORHAN ATABAY, EREF SERVER ERSOLMAZ, HATCE ERDOAN

ABSTRACT
Steering systems take a significant role on safety and comfort in road
vehicles. Driving pleasure is highly associated with the forces on the steering
wheel, which are depending on road conditions, speed of the vehicle, hydraulicelectric power steering assistance and the angle of steering wheel. These forces
are transmitted over the tires and the steering system to the steering wheel.
Steering system test benches are used for checking durability, evaluating
performance and investigating characteristics of these systems. Steering system
tests are mostly done as subjective testing which depend on test drivers and
vehicle level field testing. Extensive subjective testing results in a waste of
valuable development time and introduce high test and development budgets
with the actual increase of vehicle variants especially those with electric
steering assist functions. Due to these facts steering system testing and
development moves to the laboratories and Hardware-In-The-Loop testing
devices to overcome these situations.
Within the scope of this work, to simulate the real kinetic and kinematic
relations on a steering system, 3 axis and 5 axis steering system test benches
are designed and constructed in OTAM Laboratories as a modular structure in
order to research and develop various steering systems independently from
vehicles. In addition to the durability, performance and characterization tests
for a steering system, a driving simulator can also be coupled with the whole
system to perform driver-in-the-loop tests. The driving simulator setup enables
to check the subjective feeling of different setups with respect to different
hardware components and steering-ECU software evaluation steps.

INTRODUCTION
Steering systems are among the most significant subsystems for road
vehicles in terms of a controllable, safe and comfortable driving. Although this
importance, it is obvious that there is not enough effort in the industry and
academia for steering system evaluation in the laboratory. According to
benchmark surveys, there are only a few companies which design steering
system test benches and they have mostly systems with a few specific aims. The
presented test benches in this study have a modular and flexible design which is
helpful for analyzing durability, evaluating performance and investigating
characteristics of a steering system together.
At the present time, automotive steering systems are assisted by power
systems in order to share the necessary force for steering wheel between driver
and the assistant system. As an assistant system, electric power steering
systems have gained attention rather than conventional hydraulic power
systems because of their environmental friendliness, functionality and energy
efficiency. Corresponding to development of electric power steering systems,
problems which are related to adaptation, characterization and reliability
emerge and laboratory testing system requirements increase.
Additionally, increment of vehicle variety day by day, limited development
time and budgets make essential the movement of steering system testing to
the laboratories and Hardware-In-The-Loop testing devices instead of carrying
out the steering system characteristic optimization by experienced test drivers
being subjective. It is known that steering reaction torque is an important
information for drivers since it has significant influence on vehicle
maneuverability. Therefore, one of the most important point is to simulate
steering feeling precisely while designing the test bench. Youchun Xu et all
(2009) talked about a test-platform which is designed on the basis of the
steering system of the vehicle can manipulate directly the steering mechanism
in their studies. They used a DC motor for steering wheel rotation in the
Hardware in the Loop Simulation Test Platform and provide a tool to research
and analyze the steering control algorithm. Besides the steering feeling
simulation significance, by increasing the features such as safety, importance of
environmental protection, and fuel efficiency, electric power steering (EPS) has
been pervaded. Segewa et all (2005) mentioned a steering Hardware in the
Loop (HIL) simulator development for the steering system in their paper. An AC
servomotor and a ball screw are used to transmit force to the steering system
ball joints. And also Chih-Jung Yeh et all (2007) talked about a test bench for
electric power steering systems tuning and validation in their article in 2007.
They have developed a test bench by using force feedback motors as rack force
generating elements. Although researches recently carried by Yongsheng IIu et
all (2004), Masahiko Kurishigc et all (2000) and A.T. Zaremba et all (1998) found
that the EPS test bench use springs for the steering load setting generally, in
this study direct drive electric motors are used instead of springs or small DC
motors with gearboxes.

In order to overcome these problems related with steering system tests, an

original steering system test bench is designed for characterization, durability,
optimization and performance testing for both current and future vehicles. The
test bench is controlled and automated also by an in-house software and a
comprehensive vehicle dynamics module is coupled with the system in order to
control steering tests. Another remarkable point for the designed test bench is
to provide testing independent of full-vehicles. Due to its original design,
steering system test bench enables development and validation testing for both
OEM and suppliers on their steering systems and sub-components. The test
bench is designed as a 3 axis and a 5 axis steering system test bench for all
passenger cars and light commercial vehicles.

3 Axis Steering System Test Bench

5 Axis Steering System Test Bench

The power and force ratings of the 3-axis steering system test bench are
foreseen for passenger cars. In addition to mentioned tests above for a steering
system, a driving simulator can be also coupled with the whole system to
perform driver-in-the-loop tests.

MARKET SITUATION
All companies which give usable information about their systems in the
market are analyzed in order to observe necessities about steering system
testing. According to these analyses it is founded that, each company has
specialized on specific setups. One of the companies has presented a fully
hydraulic 5 axis steering system test bench. The most distinctive property of this
test bench is to use a hydraulic steering wheel motor and situate all actuators
into a compact construction. Due to the valves high oil transfer rate, it is
estimated that the system has notably great size of tank and pump.
Another company has used only 3 direct drive rotary elements for the test
bench. Two of them are used for rack forces and the other is used for steering
wheel motor. The most distinctive property of this test bench is to have
Hardware in the Loop tests in a 3 axis test system configuration. The test bench
of the steering system comes in the forefront with testing capabilities rather
than multi axes variety.
One more company has produced a test bench in order to test mainly
electric power steering (EPS) systems. The test bench consists of only electrical
linear actuators. Due to these linear actuators, the test system bench is more
dynamic than the other systems with hydraulic actuators.
A different company has designed again a column type and a rack type
electric power steering (EPS) test system bench to realize performance,
durability and road simulations of steering systems at variable humidity and
temperature. The test bench is able to simulate driver behavior, road vibration,
and rack forces at the right and left ball joints. For this purpose, pinion driver
robot, hydraulic servo actuators for right and left wheels load and a distinct
feature compared to other systems, a Wobble actuator are used in the test
bench.
A company else has designed a 3 axis steering system test bench which has
a steering wheel robot simulates driver behavior on the steering wheel while 2
hydraulic cylinders apply the variance of load and displacement to the steering
rack.
In addition to these companies, one company has designed a fully hydraulic
test system bench which allows different tests as 3, 4 and 5 axis. The main
difference between 3 and 4 axis system test bench is wobble actuator which
allows shock tests on the tower module in order to simulate front crashing. 5
axis system test bench is designed for durability and simulation tests for
mechanical and hydraulic steering boxes.

DEVELOPMENT APPROACH
The steering system test bench is designed as a 3 axis and a 5 axis steering
system test bench with a modular and flexible structure. The 3 axis steering
system test bench has a very accurate positioning capacity because of the
torque motors which are used as systems rack force actuators. Moreover, it is a
faster and more dynamic system than the 5 axis system test bench. In this way,
getting sensitive steering characterization with desired accuracy is allowed. The
3 axis system test bench is composed of one direct drive motor behind the
steering wheel and two torque motors for the rack forces.
The 5 axis steering system test bench serves from passenger cars up to light
commercial vehicles with intend of testing durability. The test bench provides a
wider force range than the 3 axis system test bench. In addition to 3 degrees of
freedom, the test bench has additional 2 degrees of freedom with jounce and
rebound effects. Servo hydraulic actuators for vertical and lateral forces have
hydrostatic bearings and 25 kN and 15 kN maximum force levels, respectively. A
torque motor which is assembled on steering shaft constitutes the fifth axis of
the test bench.
Development approach is started with assembling trials between vertical
and horizontal pistons for a 5 axis steering system test bench. Primarily, wheels
(wheel carrier) movements have to be taken into account while designing the
wheel side of the test bench.

Wheel Movements

Over 20 trials are examined and elected due to the technical and budgetary
reasons; like number of parts, high precision or high durable parts, complexity,
kinematic locking, systems volume, etc.

Design Trials
The design team is then left with the most appropriate 3 design options.
Within these options, the aim is to obtain the most appropriate hydraulic
actuator positioning which has the minimum hydrostatic bearing forces. To
briefly summarize 3 design trials; in the first trial, horizontal cylinder is
positioned vertically to the test bench, and cylinder is connected to fixing unit
with cardan joint, at the end of the cylinder there is a force transmission
element which transfers the force with 180 degrees angle. In the second trial,
cylinder is positioned parallel to the test bench and fixed to its plate. To provide
freedom of movement, a rod attached to cylinders rod with cardan joint. This
type of assembly makes the unit two times longer than the other 2 trials. Its
force transmission element transfers the force with 90 degrees angle. The third
and the last trial are very similar to first trial, but it is positioned parallel to the
test bench and its force transmission element is same with second trial. These 3
design trials are analyzed by using kinematic software in more detail. According
to these analyses, it is obviously seen that those 3 design trials kinematic results
are similar to each other. Also, bearing forces on horizontal cylinders are as low
as not to damage cylinder hydrostatic bearings. One of the layouts is preferred
among these 3 options due to position of horizontal cylinders. Nevertheless, the
third design is distinguished with its smaller volume Thus, third design is
preferred for all critical points.

ADAMS Designs

3-D DESIGN of the MODULAR TEST SYSTEM

3 Axis 3-D Design
The steering system test bench modules which are designed as a modular
structure in order to provide a flexible system are explained below:

Rack motor module applies rack force (lateral force) in the 3 axis
steering system test bench.

Rack Motor Module

Rack module provides fixing of steering systems gear box.

Rack Module

Tower module provides adjustment of steering systems height,

angle and position.

Tower Module
Hanger module is used for representing the assembling point
between steering system and vehicle body.

Hanger Module

Middle module plate is designed to provide movement of hanger

module and tower module as assembled together. The reason of
using the middle module plate instead of middle module is to to
prevent unnecessary length of chassis which is assembled to torque
motors. Because the torque motors are shorter than hydraulic
cylinders.

Middle Module Plate

5 Axis 3-D Design

The most critical point for the steering system test bench design is to create,
manufacture and configure the 5 axis steering system test bench. Cooperative
axes in the test bench have not to create load on each other. This setup is
succeeded:
1. Choosing appropriate cardan joints which allow piston movements in
appropriate directions
2. Designing suitable assembling parts.
3. Using hydrostatic bearing cylinders (hydraulic actuators) and increasing
cylinder rod thickness.

The steering system test bench modules which are designed as a modular
structure in order to provide a flexible system are explained below:

Rack module is a common module for both the 3 axis and 5 axis
steering system test benches. It provides fixing of steering systems
gear box.

Rack Module
Tower module provides adjustment of steering systems height,
angle and position.

Tower Module

Hanger module is used for representing the assembling point

between steering system and vehicle body.

Hanger Module
Middle module is designed to provide movement of hanger module
and tower module as assembled together.

Middle Module

Cylinder module provides transmitting vertical forces and

horizontal positions to the ball joints of tested steering system.

Cylinder Module

DESIGN VERIFICATION
Designing of all the mechanical parts and systems support structure is
completed in computer environment and after the manufacturing process
comes the assembling of parts. The modules and their assembling details are
explained below for both the 3 axis test system bench and 5 axis test system
bench:
3 Axis Design Verification
1.

Rack Module

Rack Module Assembly for 3 Axis Test Bench

2.

Tower Module

Tower Module Assembly

3.

Hanger Module

Hanger Module Assembly

4.

Middle Module Plate

Middle Module Plate Assembly

5.

Rack Motor Module

Rack Motor Module Assembly

Rack module, tower module and hanger module are common for both 3 axis
and 5 axis system test benches. Rack module, tower module and hanger
module are assembled on the middle module plate. Rack motor module
simulates lateral forces in the test bench.
One of the most important modules in the test bench is the tower module.
It is designed as a highly flexible structure, thereby each part of the module is
almost movable or knockdown. In addition to fix of steering systems tower
with the position and angle on the vehicle, tower module undertakes fixing of
steering motor and torque sensor which measures torque on the steering
motor.
As a result of functional testing in the prototype phase, it is observed that
the system gives similar results according to tests and trials on virtual
environment (MSC/ADAMS).
The working conditions are summarized below
Steering Wheel Rotation: +/- 1080
degree
Steering Wheel Velocity &
Acceleration: 2000 degree /s (35
rad/s)
Steering Wheel Motor Moment:
100 Nm (continuous)
Rack Forces (Lateral) Actuators: 2
torque motors
Rack Forces (Lateral) Capacity:
3350 N (continuous), 11825 N
(peak)
Number of Axes: 3 (2 lateral
forces, 1 steering wheel motor
moment)

Dynamic Rack Displacement

Working Range: +/- 125 mm
Rack Force Actuator Velocity: 100
rpm

Dimensions: 2000 x 3000 mm

Stand Control: NI CRIO
Steering Wheel Actuator:
Electric Motor

Communication:
Ethernet

CAN &

5 Axis Design Verification

1.

Rack Module

Rack Module Assembly for 5 Axis Test Bench

2.

Tower Module

Tower Module Assembly

3.

Hanger Module

Hanger Module Assembly

4.

Middle Module

Middle Module Assembly

5.

Cylinder Module

Cylinder Module Assembly

Rack module, tower module and hanger module are common for both 3 axis
and 5 axis system test benches. Rack module, tower module and hanger
module are assembled on the middle module.
A cylinder module is used in the 5 axis system test bench. Horizontal and
vertical hydraulic cylinders are assembled on each of two cylinder module. Rack
motor module which is situated both at the right side and the left side simulates
horizontal forces and stands in the 3 axis system test bench.
One of the most important modules in the system is the tower module. It is
designed as a highly flexible structure; thereby each part of the module is
almost movable or knockdown. In addition to fix of steering systems tower
with the position and angle on the vehicle, tower module undertakes fixing of
steering motor and torque sensor which measures torque on the steering
motor.
The cylinder module which provides 5 axis function of the steering system
test bench distinguishes the system from other existing steering system test
benches. The cylinder module is formed by assembling of two distinct cylinder
and ball joints of testing steering system with a special design.
As a result of functional testing in the prototype phase, it is observed that
the system gives similar results according to tests and trials on virtual
environment (MSC/ADAMS).

The working conditions are summarized below

Steering Wheel Rotation: +/- 1080
degree
Steering Wheel Velocity &
Acceleration: 2000 degree /s (35
rad/s)
Steering Wheel Motor Moment:
100 Nm (continuous)
Rack Forces Lateral Actuators
(Max): 15000 N
Rack Forces Vertical Actuators
(Max): 25000 N
Number of Axes: 5 (2 lateral
forces, 2 vertical forces, 1
steering wheel motor
moment)

Rack Displacement Working Range

(Lateral): +/- 60 mm (max +/- 125
mm)

Dimensions: 2000 x 3000 mm

Rack Displacement Working Range

(Vertical):125 mm

Stand Control: NI CRIO

Communication: CAN & Ethernet

Steering Wheel Actuator:

Electric Motor

DRIVING SIMULATOR
A driving simulator software is also cooperating with the steering system
test bench in order to perform characterization tests. This Hardware in the Loop
(HIL) system setup incorporates a two track vehicle dynamics model in a
programmed virtual environment. The communication between the test system
and the simulator software is setup with TCP protocol. A suitable and
ergonomic driver cabin is also designed for subjective testing with real drivers.

Whole System

CONCLUSION
Consequently, an original steering system test bench is designed as both 3
axis and 5 axis steering system test benches with a modular structure. This
design allows life-cycle, durability, performance and characterization tests of
steering systems of passenger cars up to light commercial vehicles.
The steering system test bench is designed as an original structure.
Correspondingly, a patent application process continues for this design.

REFERENCES
Chih-Jung Yeh, Shih-Rung Ho, Ming-Chih Lin, Tsung-Hsien Hu and Tsung-Hua
Hsu, 2007, Development of a Test Bench for Tuning and Validating Electric
Power Steering Control Method, IEEE, O-7803-9761-4/07 pp.618-622
M.Segawa M.Hgashi, S.Nakano, M.Shino, M.Nagai, 2005, Development of
Simulator for Evaluation of Steering Systems, Koyo Engineering Journal English
Edition, No.168E
Youchun Xu Xiao Wang Xianbing Zeng Yongsheng Peng Yongjin Zhang Yi Yuan
Hongquan Liu, 2009, A Hardware-in-loop Simulation Test-platform For the
Intelligent Vehicle's Steering Control System, IEEE, 978-1-4244-3504-3/09