Steer-By-Wire Steering Redundancy for Failure Safety

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Solution Overview

Problem

Steer-by-wire steering systems lack sufficient failure safety due to the absence of a mechanical connection between the steering wheel and the toothed rack, necessitating a design that ensures reliable operation even in the event of component failures.

Innovation Solution

A steer-by-wire steering system with redundant sensor and actuator units, each supplied independently by the vehicle electrical system, and dual processing paths with independent power supplies, allowing for continuous operation even if individual components fail.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical connection is used between the steering wheel and the toothed rack, then the steering system has inherent mechanical reliability, but the system cannot achieve steer-by-wire functionality

Engineering Contradiction:
Improvesteering system reliabilityVSAvoidsteer-by-wire capability
Core Design Contradiction:
ReliabilityVSExtent of automation

Solution Approach 1:

The patent replaces the traditional mechanical connection between the steering wheel and toothed rack with an electrical system. Sensors detect the steering wheel position and send electrical signals to actuators that control the toothed rack, eliminating the need for direct mechanical coupling while maintaining steering functionality through electrical actuation.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The steering system is divided into separate functional modules: a steering wheel with sensors for detecting driver input, a processing unit for interpreting signals, and an actuator unit with a toothed rack for executing steering commands. This segmentation allows independent optimization of each module and enables the steer-by-wire architecture by decoupling the mechanical components.

Inventive Principle:
Principle #1Segmentation

2Device complexity

If the sensor is supplied with electrical energy via the steering unit, then the system structure is simplified, but the failure safety is reduced

Engineering Contradiction:
Improvesystem structure complexityVSAvoidfailure safety
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The electrical power supply system is segmented into independent sources: the sensor receives power directly from the vehicle electrical system, while the steering unit has its own separate power supply. This segmentation creates electrical independence between components, ensuring that a failure in one power supply does not affect the other, thereby maintaining system functionality and improving failure safety.

Inventive Principle:
Principle #1Segmentation

3Reliability

If redundant sensor and actuator units with independent power supplies are implemented, then the failure safety is increased, but the device complexity is increased

Engineering Contradiction:
Improvefailure safetyVSAvoidsystem complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system incorporates redundant sensors and actuators with independent power supplies as a preventive measure against component failures. This redundancy acts as a cushion against system failures, ensuring that if one sensor or actuator fails, the redundant component can take over and maintain steering functionality, thereby prioritizing reliability over minimal complexity.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12403956B2Steer-by-wire steering system
Publication Date: 2025.09.02 ZF AUTOMOTIVE GERMANY GMBH
  • US12403956B2 patent drawing
  • US12403956B2 patent drawing
  • US12403956B2 patent drawing

AI summary

A steer-by-wire steering system for a vehicle is disclosed, having a steering wheel, at least one sensor for capturing a steering angle of the steering wheel, a processing logic unit for determining a wheel setting angle requirement on the basis of the captured steering angle, and an actuator unit for setting a wheel setting angle at wheels of the vehicle according to the wheel setting angle requirement determined by the processing logic unit. The sensor is electrically connected directly to the vehicle electrical system and is supplied with electrical energy via the latter.