In the realm of automotive innovation, the quest for safer, more efficient steering systems for improved driver ‘feel’ drives relentless research and collaboration. Dr. Tom Hardy, Senior Applications Engineer at Nylacast Automotive, and Pascal Tuszewski, Project Manager Mechanics at ThyssenKrupp, recently delivered their joint efforts in a technical paper presented at the prestigious Next Generation Steering Systems Summit held from 23 – 24 April in Detroit, USA. The focus of this research was titled: “Optimising gear manufacturing to enhance Torque to Rotate (TTR) performance in Electric Power Steering (EPS) applications”.
Nylacast Automotive, renowned for its expertise in cast polymer gears for safety-critical applications, collaborated with ThyssenKrupp, a leader in innovative mechanical solutions for power steering systems, with the joint aim to elevate the steering feel of automotive systems while enhancing motor performance. Thus, ultimately ensuring a smoother and safer driving experience.
The collaboration stemmed from a shared commitment to the belief that steering is a safety-critical system, it simply cannot fail. With this ethos driving their efforts, Nylacast and ThyssenKrupp worked on a thorough testing and optimisation strategy.
The testing process, from ‘Surface Evaluation’ to ‘TTR measurement post-run-in’, was meticulously performed. Leveraging Design of Experiments (DOE) principles, the teams systematically explored parameters impacting TTR performance. Samples were manufactured and subjected to comprehensive testing, culminating in positive and progressive results.
The outcome portrayed that through optimised gear cutting parameters, Nylacast and ThyssenKrupp were able to achieve a significant 40-50% reduction in TTR metrics. This achievement not only met customer requirements but also translated into tangible benefits for drivers, with improved steering feel and enhanced motor performance.
As the 7th Next Generation Steering Systems Summit comes to an end, we wish to extend our gratitude to RedCabin for organising and hosting a highly informative conference. A special acknowledgment is reserved for Pascal Tuszewski for his positive and data driven collaboration and support.
