QC/T 1083-2017Controllers for automotive electric power steering (English PDF)

3.1 Controller working properly

The automobile electric power steering device (hereinafter referred to as device) shall be installed on the test bench; the controller, motor and sensor are normally connected; the whole vehicle signal is normally input. After the power is turned on, rotate the steering wheel device left and right to assist normally.

3.2 Controller failure

The controller is considered invalid in case one of the following conditions:

a) During the function test, due to the controller, there is non-smooth, stuck, obvious […]

4.1.4.2 The allowed voltage change range

a) 9V ~16V (nominal voltage of 12V)

b) 20V ~ 32V (nominal voltage of 24V).

4.1.5 Self-test function and fault code

The controller shall have self-test function, and can store the fault code.

4.2 Performance

4.2.1 Function

During the process of manually rotating the steering wheel at different speeds, it shall be smooth, without stuck or obvious inertia delay.

4.2.2 Power current characteristics

At different speeds, the relationship between the input torque and the output current, i.e. the power current characteristics, shall meet the manufacturer's requirements. The symmetry of the curve at each vehicle speed (allowed to be represented by 0 km/h speed) shall be >= 90%.

4.2.3 Failure alarm

The controller shall have the function of failure alarm. When the motor, sensor and the entire vehicle input signal are detected to be abnormal or controller itself fails, the controller shall output the fault alarm signal. In the event of any fault, the mechanical part of the device shall work properly.

4.2.4 Resistance to power supply voltage fluctuation

The controller shall have the ability to adapt to fluctuations for the power supply voltage. When the vehicle power supply changes within the range of 9V ~ 16V (nominal voltage of 12V) or 21.6V ~ 32V (nominal voltage of 24V), the controller shall work properly. After the test, the variation of the power current characteristics shall be < 15%.

4.2.5 Reverse connection of power supply and voltage overload

The controller shall have the ability to resisting the reverse connection of power supply and voltage overload. After test, the controller can work properly.

4.2.6 Drop

After the drop test, the controller shall work normally; and meet the requirements of […]

4.3.8 Electromagnetic compatibility

4.3.8.1 Radio disturbance characteristics

The controller shall meet the requirements stipulated in GB/T 18655, and shall reach the Class-I level of the limit value.

4.3.8.2 Electromagnetic radiation immunity

The controller shall meet the requirements stipulated in GB/T 17619.

4.3.8.3 Electrical disturbances caused by electrostatic discharge

The controller shall conform to the provisions of GB/T 19951, and reach the Class-A requirements.

4.4 Reliability

4.4.1 Fatigue test

4.4.1.1 After the fatigue test, the controller is not allowed to have any failure.

4.4.1.2 It shall meet the requirements of 4.2.1.

4.4.2 Vibration

4.4.2.1 After the vibration test, the controller is not allowed to have any cracks or breaks.

4.4.2.2 It shall meet the requirements of 4.2.1.

5.1 Test conditions

5.1.1 Temperature deviation

This Standard specifies that the temperature deviation in the test method is ±2°C, unless otherwise specified.

5.1.2 Test voltage

This Standard specifies the test voltage is 12V±0.5V (nominal voltage of 12V) or 24V±1V (nominal voltage of 24V), unless otherwise specified.

5.1.3 DC power supply for test

A vehicle battery or a DC stabilized power supply with a ripple ratio of <=0.5% can be used.

5.1.4

The installation of the controller shall be performed as per the test requirements.

5.1.5

Only the drop test and connector strength test can be performed alone, other tests of the controller shall be carried out together with the device.

5.1.6 Test apparatus requirements

5.1.6.1 In the temperature range of 23°C±5°C, the accuracy of the measurements for torque, force, displacement, rotation angle, speed, current, and voltage shall be no less than 0.5%FS.

5.1.6.2 In the temperature range of 23°C±5°C, the resolution for temperature measurement shall be no less than 1°C.

5.1.6.3 In the temperature range of 23°C±5°C, the resolution for humidity measurement shall be no less than 10%RH.

5.2 Performance

5.2.1 Function

Install the device on the test bench; the system works properly; the input end is in the straight running position; while the output end is applied test load (evenly divided into 5 points, including 0 and Tc); the speed is divided into 5 points in the range of 0~Vmax (by the interval of 5km/h~20km/h); manually turn the steering wheel to left and right for test, feeling smooth and no stuck.

5.2.2 Power current characteristics

5.2.2.1 Install the device on the test bench, the system works properly; the input end is in the straight running position; rotate the input end at a constant speed; so that the load on the output end reach the rated load; set different speeds (evenly divided into 5 points, including 0 and Vmax); record the relationship curve between the input torque and output current under each speed (Figure 1).

5.2.5.2 Voltage overload

5.2.5.2.1 If the nominal voltage is 12V, the input end is connected to the +24V power supply for 1min; after the test is completed, check whether the controller works properly.

5.2.5.2.2 If the nominal voltage is 24V, the input end is connected to the +32V power supply for 1min; after the test is completed, check whether the controller works properly.

5.2.6 Drop

5.2.6.1 Place the controller at the height of 1m (the lowest point of the controller) by the longest diagonal line vertically downwards; then drop it freely (the ground is hard ground); after the test is completed, check whether the controller works properly.

5.2.6.2 Then perform the tests in 5.2.1~5.2.5.

5.2.7 Connector strength

5.2.7.1 The controller connects to the corresponding connector; apply a force of 147N in the direction of insertion and plugging for 5s; do it 5 times continuously; then apply a force of 49N in the up and down, right and left directions for 5s; do it 2 times separately. After the test is completed, check whether the controller works properly.

5.2.7.2 Then perform the test in in 5.2.1~5.2.5.

5.2.8 Power consumption at static state

If the controller works properly, when the ignition switch is off, measure the current flowing through the controller and power supply line.

5.3 Environment

5.3.1 High temperature

5.3.1.1 The device works properly; perform the test as per the test B: high temperature test method stipulated in GB/T 2423.2.

5.3.1.2 Place it for 96h at a temperature of +85°C or +105°C (controller is installed outside the cab).

5.3.1.3 After the test is completed, directly take test in the test chamber as per 5.2.1; check whether the controller works properly.

5.3.2 Low temperature

5.3.2.1 The device works properly; perform the test as per the test A: low temperature […]

5.3.8.3 Electrical disturbances caused by electrostatic discharge

The controller works properly. According to the Class-III test level stipulated in GB/T 19951, perform the test at the speed of 8km/h. The measuring points shall be around the connector and on the edges of the upper surface of the housing of motor, sensor and controller; the number of the measured points shall be no less than 10.

5.3.8.4 Electrical transient conduction along the power line

The controller works properly. Perform the test according to Class-III test level stipulated in GB/T 21437.2.

5.4 Reliability

5.4.1 Endurance test

5.4.1.1 The controller works properly. Simulate the current output state of the entire vehicle; ensure the maximum output of the controller.

5.4.1.2 Finish a total of 7750000 current output periods for 125000 cycles at 25°C; the current output period for each cycle can refer to Table 2. The current output waveform for each current period can refer to Figure 5 (allow to enter into the thermal protection mode designed by the manufacturer).

5.4.1.3 After the test is completed, the controller can work properly.