Electric Steering Made Better

Electric Steering Made Better

The intricacies and complexities relating to electric steering places a heavy burden on remanufacturers to be able to thoroughly test a product. Gone are the days of a simple hydraulic remanufacture where all products fit into a very similar mould. The requirements for testing modern steering go far deeper.

A remanufactured EPS product requires a mechanical and electronics overhaul; including PCB component replacement, reprogramming and plastics repairs. An understanding of the diagnostics and software that helps the product communicate with the vehicle are essential. However, most importantly, is a true road feel test.

To highlight the challenges faced, we tested a Ford Focus EPS steering rack with a commonly used simulator. This equipment provides the user with a host of data. But what exactly does it test and is this enough to safely bring the product to market?

As the test-rig is attached to the product and CAN-bus messages are sent and received, the operator is able to remove fault codes using a scan tool and they are able to see communication. The ECU, sensors and motor are all engaged, and, on this basis, we commonly see remanufacturers concluding that the product is ‘fit for purpose’, when in reality it isn’t. Unless the product is given a true road feel experience, it simply cannot be deemed ‘fit for purpose’.

Our test of the Ford Focus initially seemed successful, However, when the gaiter was removed, the mechanical element of the steering rack was poor. The rack bar was heavily corroded due to a failed gaiter and water ingress. This product would have failed within a very short time on the vehicle.

At Complete, we can test a product, so that it actually thinks it is on the car. The product is given resistance, braking, speed signals, ice conditions, even special features from the vehicle such as City Mode, ASR, VDC are tested. Angle sensors are balanced accurately to reduce drift or creeping and every element of the product is tested to firmly understand that it is really ‘fit for purpose’.

Our company ethos is MADE: Manufacture, Application, Distribution, Education. Education is very important to us and we are extremely interested in improving the knowledge of our customers for all EPS Steering related matters.