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The automotive steering system is evolving from EPS to advanced Steer-by-Wire (SBW) technology. As a core element of chassis technology, its performance has a crucial impact on vehicle handling stability and driving safety. To ensure the controller’s performance is optimized before the vehicle's final assembly, Hardware-in-the-Loop simulation testing has become an indispensable part of the development process.

VCARSYSTEM's Solution

VCARSYSTEM Full-Function Steering Hardware-in-the-Loop (HIL) Test System delivers continuous simulation across electrical, mechanical, and control domains, enabling comprehensive testing and validation of motor control boards, inverter components, as well as steering control algorithms and functional safety diagnostics, with full compatibility for both Electric Power Steering (EPS) and Steer-by-Wire (SBW) systems. Capable of reproducing real-world steering scenarios including vehicle dynamics characteristics, road conditions, and driver maneuvers to complete full functional and performance evaluation of the steering system, this controllable, highly repeatable test environment provides reliable verification evidence for steering system components and control strategies, and facilitates the engineering readiness and implementation of relevant R&D events prior to real-vehicle testing.

HIL SYSTEM

VCARSYSTEM provides a complete HIL SYSTEM that covers multiple key areas, including the new energy three-electric field (BMS/VCU/MCU), ADAS autonomous driving field (ACC/LKA/AEB, etc.), vehicle body field, traditional automotive power field (EMS/EPS/ESP, etc.), and cockpit field, offering comprehensive hardware-in-the-loop testing services.

VCAR EM

VCAR EM is an engineering configuration software developed by VCARSYSTEM for the HIL platform, which can perform HIL engineering related configurations. It includes GPIO signal configuration, CAN/CANFD, LIN, Ethernet and other bus communication configurations, board hardware configuration, simulation object model import, signal mapping relationship configuration, real-time host multi-tasking allocation and management configuration, engineering compilation and other functions. At the same time, the software supports multi-tasking allocation management and multi-device cascade configuration, meeting different test scenario configuration requirements.

ADVANTAGES

Signal-Level Full-Parameter Simulation & Control Strategy Pre-validation

- Enables pre-validation of steering control strategies, significantly shortening your R&D cycle and reducing hardware trial-and-error costs.
- Supports convenient full-parameter configuration of motors and inverters (pole pairs, phase resistance, inductance, flux linkage, initial state, inertia, friction coefficient, etc.), accurately simulating PWM-controlled DC-AC conversion characteristics, IGBT/diode switching characteristics, and enables rapid simulation of various inverter and motor fault conditions.

Power-Level Wide-Range Adaptation & Hardware-Level Fault Simulation

- Covers full testing requirements of all steering power units with one single system, eliminating multi-equipment switching and reducing test investment.
- Adapts to 300W-20kW power range, 12V/24V/48V platform voltage, compatible with Surface-mounted Permanent Magnet Synchronous Motors (SPMSM), supports peak single-motor current ≥150A, and accurately simulates motor hardware faults including inter-phase short circuit, phase offset and phase loss.

High Reliability Long-Term Operation & Lifecycle Cost Reduction

- Delivers maintenance-free continuous stable operation, greatly reducing equipment downtime and full-lifecycle operational costs.
- Adopts a wear-free component design with fire resistance, supports uninterrupted long-duration testing in harsh environments, and meets all long-cycle test requirements.

High-Efficiency Force Transmission & Compact Structure Optimization

- Reduces test site footprint, deployment costs and equipment failure rate, while improving load simulation accuracy.
- Adopts direct force generation technology and simplified mechanical structure, eliminates intermediate transmission parts to reduce mechanical loss and failure points, simultaneously cuts equipment weight and installation space, and improves force transmission efficiency and load simulation accuracy.

High-Stiffness Drive & Ultra-High Precision Testing

- Ensures test accuracy and repeatability under all working conditions, achieving 1:1 matching with real-vehicle operating conditions.
- The drive unit features high static and dynamic stiffness, delivering stable output under high load and high speed conditions, realizes ultra-precise motion control with positioning accuracy <1µm, and meets the most stringent accuracy requirements of steering testing.

Robust Environmental Adaptability & Superior Shock/Vibration Resistance

- Greatly improves equipment durability and service life, enabling stable and reliable operation in complex and harsh environments.
- Features excellent shock and vibration resistance, maintains stable operation in complex and harsh test environments, and adapts to long-term testing requirements in all scenarios.

Multi-Platform Rapid Adaptation & Ultra-Fast Real-Time Response

- Seamlessly adapts to various autonomous driving test platforms, ensuring the accuracy and reliability of high-speed real-time testing.
- Seamlessly adapts to power steering systems of various autonomous driving platforms, enables rapid switching without extensive software and hardware reconstruction, features millisecond-level system response and microsecond-level component update capability, eliminates system hysteresis error, and meets high-speed real-time testing requirements.

FUNCTIONS

Steering Wheel Simulation Input

For mechanical-level testing, the integrated steering robot delivers a high-dynamic input torque of >100 Nm with angle control accuracy of <0.1°, enabling precise simulation of real-world steering maneuvers for reliable validation testing.

Linear Motor Load Simulation

Delivers a maximum simulated output force of 20 kN (force measurement accuracy: 0.25% FS), a linear motion speed of 1 m/s, and 0.1 mm positioning accuracy via direct drive technology (zero backlash), enabling high-precision load and motion simulation across real-world operating conditions.

Adaptive Mechanism Design

Enables left-right and hand-drive adjustment with 0.25 mm positioning accuracy and a maximum positional tolerance of <5 mm, adapting to diverse steering gear installation orientations.

High-Dynamic Performance (Speed & Acceleration)

Delivers exceptional dynamic performance with high speed and rapid acceleration, enabling simulation of extreme steering maneuvers to meet complex testing requirements.

High-Speed & High-Resolution Acquisition

Incorporates VCARSYSTEM’s proprietary high-speed measurement system (max. sampling rate ≥2 MHz, resolution ≥16-bit) to acquire accurate, high-quality test data.

Complete Automatic Calibration Function

Integrates a fully automated calibration function for ADAS-enabled power steering systems, streamlining test preparation workflows and ensuring consistent accuracy.

Comprehensive Steering Verification & Simulation

Encompasses all full-spectrum key steering functions, simulates diverse driving conditions, road characteristics, and vehicle operating states, and injects a comprehensive suite of fault scenarios to thoroughly validate steering system performance, reliability, and adaptability across all operating conditions.

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