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Electronic Power Steering Jack D. Michaels Training Center

and effects on wheel alignment
services
Conway Arkansas
Thursday, July 08, 2010
Sales and Technical Training Support

Electromechanical Power Steering Systems (EPS)

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 The move

Conventional hydraulic power Electric power steering systems

steering systems

Why?

Electromechanical Power Steering Systems (EPS)

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Hydraulic Power Steering
Systems

Controller
Horsepower is wasted on hydraulic
Oil reservoir power steering systems because the
pump, on most cars, is constantly
Pump
Hoses operating and pumping fluid
Valve
This action requires power from the
Rack and pinion
engine and the result is a decrease in
fuel economy

Electromechanical Power Steering Systems (EPS)

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Hydraulic Power Steering
Systems

Most power steering systems work by using a

belt driven pump to provide hydraulic
pressure to the system.

Electromechanical Power Steering Systems (EPS)

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Hydraulic Power Steering
Systems

This hydraulic pressure is generated

by a rotary-vane pump which is
driven by the vehicle’s engine

As the speed of the engine

increases, the pressure in the
hydraulic fluid also increases, hence
a relief valve is incorporated into the
system to allow excess pressure to
be bled away

Electromechanical Power Steering Systems (EPS)

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Hydraulic Power Steering
Systems

The input from the steering shaft forms the inner part of a spool-valve
assembly. It also connects to the top end of the torsion bar. The bottom of
the torsion bar connects to the outer part of the spool valve. The torsion
bar also turns the output of the steering gear, connecting to either the
pinion gear or the worm gear depending on which type of steering the car
has.

As the bar twists, it rotates the inside of the spool valve relative to the
outside. Since the inner part of the spool valve is also connected to the
steering shaft (and therefore to the steering wheel), the amount of rotation
between the inner and outer parts of the spool valve depends on how
much torque the driver applies to the steering wheel.

When the steering wheel is not being turned, both hydraulic lines provide
the same amount of pressure to the steering gear. But if the spool valve is
turned one way or the other, ports open up to provide high-pressure fluid to
the appropriate line.

Electromechanical Power Steering Systems (EPS)

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Hydraulic Power Steering
Systems

While the power steering is not being

used, i.e. driving in a straight line,
twin hydraulic lines provide equal
pressure to both sides of the steering
wheel gear. When torque is applied
to the steering wheel, the hydraulic
lines provide unequal pressures and
hence assist in turning the wheels in
the intended direction

Electromechanical Power Steering Systems (EPS)

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EPS Basic knowledge

With electro-mechanical power steering,

there is no requirement for hydraulic
assistance to support the steering

Eliminating hydraulic oil, drive belt, and hoses

from the steering system

Electromechanical Power Steering Systems (EPS)

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EPS Basic knowledge

The electro-mechanical power steering system can be

of a single pinion or a dual pinion type (steering and
drive pinions), which enable the necessary steering
force to be transmitted to the steering rack

Electromechanical Power Steering Systems (EPS)

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EPS Basic knowledge

To assist the steering, an electric motor is

actuated based on input response

The system provides the driver with assistance

depending on the driving conditions (servotronic).

Electromechanical Power Steering Systems (EPS)

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EPS Basic knowledge

The electro-mechanical power steering supports

return of the steering wheel back to the center
position via the “active return” function

This results in a well-balanced feeling and extremely

accurate straight-line stability in every driving situation

Electromechanical Power Steering Systems (EPS)

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EPS Basic knowledge

With the straight-line stability function, a force is

generated and applied to make it easier for the driver
to steer the vehicle in a straight line when the vehicle
is being affected constantly by side winds or driven
up or down hills

Electromechanical Power Steering Systems (EPS)

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EPS Basic knowledge
The Advantages of Electro-mechanical Power Steering

The electro-mechanical power steering system offers the following advantages over a traditional
hydraulic system:
• no hydraulic components, for example power steering oil pump, hoses, oil
tank, filter
• no hydraulic fluid
• space savings
• reduction in noise
• energy savings
• no complex hose and wiring system

The electric motor and control module are located directly on the steering gear

Electromechanical Power Steering Systems (EPS)

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EPS Wheel Alignment
Considerations
VW dual pinion type EPS

Electromechanical Power Steering Systems (EPS)

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EPS Wheel Alignment
Considerations
Different types of EPS assemblies

Rack mounted hydraulic Column mounted electric Rack mounted electric

Electromechanical Power Steering Systems (EPS)

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EPS Wheel Alignment
Considerations
Different types of EPS assemblies

Honda Civic rack mounted

With SAS and TQS

Electromechanical Power Steering Systems (EPS)

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EPS Wheel Alignment
Considerations
Different types of EPS assemblies

Delphi column mounted

With SAS and TQS

Electromechanical Power Steering Systems (EPS)

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EPS Wheel Alignment
Considerations
Different types of EPS
assemblies

BMW 7 Series
front and rear
electromechanical
steering gears

Electromechanical Power Steering Systems (EPS)

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EPS Wheel Alignment
Considerations
Different types of EPS assemblies

BMW 7 Series
front and rear
electro hydraulic
steering gears

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

Steering wheel lock

Telescoping
The entire system of the electromechanical power steering is flexible joint
structurally combined into a compact unit
high adjustment
All components, including the controller, electric motor and the
sensors necessary for the control are part of this unit
Power steering
mechanism with
torque sensor
Steering gear

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

On a conventional hydraulic
power steering system the
Telescoping flex joint
request for steering assist is
determined by the sector
shaft which is normally
situated below the flexible
coupling

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

During the electromechanical power Telescoping flex joint

steering the power assist takes place
before the flexible coupling

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Sensor housing for
Electric motor Steering angle Intermediate spindle
And torque sensor

Clutch

Torsion bar

Worm drive and drive gear

Steering shaft

Steering column adjustment

Telescoping flex Control unit for EPS

joint

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Torsion Bar

The central construction unit of the Assembly

electromechanical power steering is the torsion
bar. It makes possible by its material properties,
flexible deformation around its longitudinal axis

The torsion bar connects the intermediate

spindle mechanically with the axle of the worm
drive
Intermediate spindle

Torsion Bar

Axle with drive gear

Ball bearing
Electromechanical Power Steering Systems (EPS)
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Electromechanical Power
Steering Systems

By connecting the intermediate spindle and the

axle of the worm drive to each other the system
Mechanical
can detect a small amount of rotation and signal connections
the control unit to engage the electromechanical
power steering to assist the driver

Twist torsion bar at the beginning of a steering

movement

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

The torsion bar is now connected to a sensor

allowing the control unit to perceived the twist
and provide corrective feedback
Mechanical
connections

Twist torsion bar at the beginning of a steering

movement
Electromechanical Power Steering Systems (EPS)
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Electromechanical Power
Steering Systems
(ASSIST)
Electric Motor

The worm gear drive is located in an Housing

aluminum housing to which the electric motor

is fastened

A worm drive on is connected to the steering Rubber coupling

shaft and insulated from the electric motor
using a rubberized coupling

The ring gear is manufactured out of plastic to

reduce the noise level
Worm gear axle Worm drive

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power Steering Systems
(ASSIST)

The torque sensor

sends a signal to the
control unit

The control unit

processes the signal
and issues a power
assist command to
the electric motor
which in turn rotates
the worm gear, the
worm drive and finally
the moves the rack in
the desired direction

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems (TILT
MECHANISM)

If the steering wheel is adjusted upward, the

telescope arm is pushed together. Thus the
distance is made smaller from the steering
wheel to the steering gear

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems (TILT
MECHANISM)

If one adjusts the steering wheel downward, this

distance is increased and the telescope arm is
stretched

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Electromechanical Power Steering
Control Unit
System configuration
Sensors Actuators

Servo motor
For steering angle
And torque sensing

EPS Warning symbol

Instrument cluster If the controller determines
an error in the
electromechanical power
steering system, t the
indicator light in Instrument
Power DLC connector panel is turned “ON”

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

Sensors Torsion Bar

The steer angle sensor and that Sensor housing

torque sensor are in a housing

It sits on the axle of the worm

gear above the gear wheel. The
connection to the controller is
made by a an electrical Axle of the worm gear above the
gear wheel
connector

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

Sensors

The sensor is mounted on

the worm gear shaft

It reads the steer angle,

and/or the current position
in degrees

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

Sensors
The torque sensor is connected to
the torsion bar

It recognizes a twisting angle of the

torsion bar opposite the
intermediate spindle

If this calculated torque exceeds a

value of 0,01 Nm, then the
controller assumes a power assist
is required

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems Decoupled steering column for ease of explanation

In this illustration you see a steering column,

which is separated into an upper and a lower
part for the simplification of the explanation
Torsion Bar

Steering angle sensor Torque sensor

Electromechanical Power Steering Systems (EPS)

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Conway AR Thursday, July 08, 2010
Electromechanical Power
Steering Systems Decoupled steering column for ease of explanation

The driver begins to steer. The torsion bar is

rotated. The torque sensor rotates with the
torsion bar, supplies signals to the controller
and direction of rotation of the torque at the
steering wheel

The controller calculates the necessary torque

amount and sends a signal to the electric motor

The amount of the torque on the steering wheel

and the amount of power assist is equalized at
the steering column

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

Torque at the steering wheel

Power Assist
Effective moment

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Motor Decoupled steering column for ease of explanation

If the driver increases the torque at the steering,

the electrical motor will provide power assist

This makes the vehicle easier to steer

The twist in the torsion

bar is detected by the
torque sensor and
power assist is
commanded

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

If the driver reduces the torque at the steering Decoupled steering column for ease of explanation

wheel, the twist of the torsion bar is reduced.

The sensor supplies a smaller signal to the

controller. The controller reduces the amount of
torque assist

When the torque sensor value and the steering

angle value are equal the unit is reset to straight
ahead and the power assist is interrupted

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Decoupled steering column for ease of explanation

Active resetting Electric motor

If the driver releases the steering wheel

while driving along a curve, the torsion bar
will relax, the electric motor switches
“OFF” and the power assist is
interrupted

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Straight ahead

Active resetting Power assist

Torque request
If the torque sensor is inactive, not
torque on the steering wheel,
power assist will intervene and
straightened the fronts wheels

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

Vehicle behaviors normally associated

with wheel alignment such as pull or
drifts may be caused by
other components or systems not
directly related to the tires and wheels
themselves

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Straight ahead driving
Torque sensor and steering angle sensor aligned
SAS == TQS = No EPS Assist
Power assist interrupted

Vehicle has resumed straight ahead position

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Left hand turn torque request
Driver steers the vehicle to the left
Torque sensor detects request for left hand turn
SAS < TQS = EPS assist required

Power assist initiated

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Left hand turn torque request
Power assist initiated and the front wheels are
steered to the left

Steering angle sensor value increases

Power assist initiated

When the SAS = TQS power assist not required

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Back to center
Driver releases the steering wheel
Steering is released and allowed to come back
to center position (torque request reduction)

SAS > TQS = power assist required

Power assist initiated
Power assist returns the wheels top straight
ahead position

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Back to center
Torque sensor and steering angle sensor aligned

Power assist interrupted

Power assist interrupted
Vehicle has resumed straight ahead position

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Right hand steer torque request

Torque sensor request for right hand turn

Power assist initiated

Torsion bar begins to twist

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems
Right hand steer torque request

Power assist initiated wheels are steered to the right

Steering sensor angle value increases

When SAS = TQS power assist is interrupted

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

Driver releases the steering wheel

Steering is released and allowed to comes back
to center position (torque request reduction)

SAS > TQS = power assist required

Power assist returns the wheels top straight
ahead position

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power
Steering Systems

Driver releases the steering wheel

Steering is released and allowed to comes back
to center position (torque request reduction)

SAS > TQS = power assist required

Power assist returns the wheels top straight
ahead position

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power Steering Systems
Wheel Alignment Considerations

The relationship
between the
steering angle
sensor, the torque
sensor, and the
direction of travel is
critical for adequate
system performance

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power Steering Systems
Wheel Alignment Considerations

Trust line alignment are now the minimum alignment

That can be performed and a vehicle equipped with
EPS

If the vehicle has four wheel alignment capability

then a four wheel alignment must be performed

Always follow vehicle manufacturer’s directions and

instructions

Remember it’s all about relationships and vehicle

behavior

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power Steering Systems
Wheel Alignment Considerations
Geometric centerline Trustline

The front wheels must be aligned to the direction of

the rear wheels

The steering must be leveled, in order to minimize

electronic drift of the SAS and Torque sensors, use
EASY-TOE and avoid locking the steering wheel SAS = 0
during the front toe adjustment TQS = 0
Front wheels aligned to the
Dynamic direction of the rear wheels

Always loosen the jam nuts, and ensure that the toe
adjuster can be rotated freely before leveling the
steering wheel

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power Steering Systems
Wheel Alignment Considerations

When performing a wheel alignment it is important

not to load the rack and pinion mechanism
1. Locking the steering wheel and pushing on one wheel to re-center
2. Turn plates that so move freely (corroded or dirty)
3. Forgetting to unlock the jam nuts or radial clips and loosening the front toe
adjusters prior leveling the steering wheel

Loading the rack and pinion may cause the SAS

and TQS to be misaligned. Some systems are
sensitive to ,less than 1lbs/force
Highly recommended that the front turn plates move freely
Any restrictions in the movement may impose strain on the
This type of misalignment may cause a pull or a Steering gear and cause a pull or drift

drift
Electromechanical Power Steering Systems (EPS)
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Electromechanical Power Steering Systems
Wheel Alignment Considerations

Unlike hydraulic systems the EPS uses a feedback

system to determine the amount and duration of
assist

The steering rotation along with the vehicle’s speed

directly contribute to the amount and duration of
power steering assist

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power Steering Systems
Wheel Alignment Considerations

Vehicle aligned to the trust line,

All four wheels are parallel, the
steering wheel is leveled and centered
The SAS and Torque sensors are aligned

Not necessarily the best case scenario

for vehicle dynamics but is an acceptable
option the geometric shape of the vehicle will
affect the position of the center of gravity
Electromechanical Power Steering Systems
Wheel Alignment Considerations

Four wheel alignment provides the ideal

alignment and vehicle dynamic
behavior

All wheels are adjusted and

positioned parallel to the direction of
travel, the SAS and TQS are in line
with the direction of travel

The center of gravity is centered

within the vehicle’s perimeter

Electromechanical Power Steering Systems (EPS)

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Electromechanical Power Steering Systems
Vehicle Dynamics

Information resource:

VW of Germany
Selbststudenprogramm 225 Electromechanical Power Steering Systems (EPS)
Die Elektro Mechanische Servolenkung Snap-on Equipment
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