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Small Steering Test Bench

The setup presented here shows how a “mini” test bench can be integrated even in the smallest spaces. The “test bench drawer” is built into a 19’’ rack and can be used for many applications that absolutely require the real drive unit to be integrated in the test system. The amount of performance data of the load machines is manageable and allows for extensive mechanical tests. The example setup shows a load motor for an EPS servomotor. In closed-loop operation, a steering model that provides the target values for the load machine is computed on the real-time hardware. This virtualization of the mechanics increases flexibility, which is particularly useful for power packs (generic drive units).

Features:

  • Steering test bench for power packs of electromechanical power steering systems
  • Synchronous motor for simulating the position or the load torque acting on the drive shaft of the servomotor
  • Sensor for capturing the torque of the servomotor
  • Prepared for virtual test drives thanks to the seamless integration into the ASM Vehicle Dynamics Model
  • Integration in a standard HIL cabinet possible
  • Dimensions: 0.5 m x 0.5 m x 0.5 m (approx. 9.8 x 3.3 x 7.2 ft)
  • Weight: approx. 20 kg (approx. 44 lb)
  • Connected load: 8 kW

References:

  • Various turn-key projects for OEMs in Europe, North America, and Asia

Load motor:

Motor Characteristics
Motor Synchronous motor without transmission
Motor encoder HIPERFACE® motor feedback system
Servo amplifier LTi Servo One
Control strategy torque Forward control (motor current)
Control strategy position Cascade control with subsidiary speed and torque control (no controller on dSPACE real time hardware)
Maximum continuous torque [Nm] 6
Maximum displacement [deg] unlimited
Maximum speed [rpm] 6000

 

Steady State Control Accuracy
Torque [Nm] ±0.1 (depends on device under test and torque transducer)
Position [deg] ±0.01

 

Torque Sensor Characteristics
Measurement range [Nm] ±10
Accuracy [Nm] ±0.01

Further Information