End-to-End Validation of Electric Power Steering using Hardware-in-Loop and Vehicle Bench Systems
DOI:
https://doi.org/10.63282/3050-922X.IJERET-V7I1P136Keywords:
Electric Power Steering, Hardware-In-Loop, EPS ECU Validation, Vehicle Bench Testing, Torque Overlay, ADAS Steering, Real-Time Simulation, Model-Based Development, Fault Injection, ISO 26262Abstract
This Paper of its better steering comfort, higher fuel efficiency and ability to be used with Advanced Driver Assistance Systems (ADAS), Electric Power Steering (EPS) has been a secondary subsystem in passenger cars becoming a standard element of any present-day vehicle. A strong multi-layered validation approach is needed to make sure that its reliability is ensured under real-world and extreme operating conditions. The present paper provides an end-to-end experience of EPS validation based on Hardware-in-Loop (HIL) and Vehicle Bench Systems, which combines the simulation-based validation testing as well as the physical testing of subsystems. The methodology facilitates ECU level verification, real-time testing of actuators and complete system verification behavior, cutting down the development time and failures in the field by a significant margin. The suggested validation system combines model simulation, sensor simulation, torque overlay test, steering map testing, thermal profiles, fault injection, and closed loop dynamic testing. There is a detailed EPS functional verification workflow, communication integrity testing workflow, failure mode diagnostics workflow and durability assessment workflow. Components of cost, engineering flexibility, risk mitigation, and test coverage are among the factors that are systematically compared in the study, between the conventional vehicle validation and modern HIL-based validation. The results of the experiments prove that the number of prototype iterations reduces greatly, the quality of controlling algorithms is increased, and the correlation between testing and simulation and testing of the vehicles is demonstrated. Experiments involving a real-time dSPACE-based HIL system and high fidelity EPS mechanical rig indicate that there are only ±3 percent differences on assist torque prediction between the system and the vehicle level. Moreover, fault simulation, such as torque-sensor drift, CAN bus delay, and motor overcurrent was tested without exposing the hardware to unjustifiable risks. The results demonstrate that incorporating HIL and vehicle bench systems will result in the quicker debugging process, enhanced security, and extremely trustworthy EPS controllers in this or that situation. The paper ends with the conclusion and recommendation of hybrid validation process to use in cases of OEM and Tier-1 suppliers that would reduce the time frame of development, warranties costs, and adherence to ISO 26262 functional safety specification.
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