Steering Rack Corrosion Detection via Joggle Analysis
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Solution Overview
Problem
Steering racks in vehicles are prone to corrosion due to exposure to water, dirt, and corrosive road conditions, leading to sub-optimal performance and potential failure, especially in autonomous or semi-autonomous vehicles where self-diagnostic functions are beneficial.
Innovation Solution
A corrosion detection system comprising sensors, a processor, and a datastore that measures displacement and force applied to the steering rack, calculates the probability of corrosion using joggle characteristics and fast Fourier transform analysis, and activates a corrosion-level indicator based on the calculated probability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steering rack is exposed to water, dirt, and corrosive road conditions during normal operation, then the steering mechanism can perform its steering function, but corrosion occurs leading to sub-optimal performance and potential failure
Solution Approach 1:
The system performs preliminary detection of corrosion by monitoring steering rack characteristics (displacement, force, current) before significant corrosion damage occurs. The processor continuously analyzes these parameters to detect early signs of corrosion, enabling proactive maintenance before the steering rack fails or performance degrades substantially.
Solution Approach 2:
The system implements a feedback mechanism where sensor data about steering rack operation is continuously fed back to the processor, which analyzes changes in displacement, force, and current characteristics. This feedback loop enables the system to detect corrosion progression and provide ongoing monitoring of steering rack health status.
2Reliability
If sensors and processing systems are added to detect corrosion, then corrosion can be detected early for maintenance, but device complexity increases
Solution Approach 1:
The system repurposes existing sensors originally designed for other steering functions to also detect corrosion. The displacement sensor, force sensor, and current sensor are already part of the steering system for normal operation, and the processor uses their existing data to simultaneously monitor for corrosion conditions, eliminating the need for separate dedicated corrosion sensors.
Solution Approach 2:
The steering rack essentially monitors itself by using its own operational data (displacement, force, current) to detect corrosion. The existing sensors that measure steering rack performance parameters provide the data needed for corrosion detection, and the processor analyzes this self-generated data to assess steering rack health without requiring external monitoring equipment.
Data Source
AI summary
A system and method for detecting corrosion in a steering rack of a vehicle based upon the performance of the steering rack in comparison to reference data collected for a non-corroded steering rack. Corrosion may be detected based upon analysis of performance data with respect to steering joggle or a data transform. Performance data may comprise displacement of the steering rack with respect to a neutral position, or the force applied to the components of the steering system.