Steering Rack End-Position Detection with Torque-Based Peak Tracking

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Solution Overview

Problem

Existing methods for detecting the end positions of a turning device, such as electric power steering systems, suffer from precision errors due to mechanism twist or backlash, and are inadequate for nonstandard installations, affecting the accuracy of reference point calculation.

Innovation Solution

A detection device and method that includes a steering angle detection unit, actuator, and torque detection unit to identify limit positions by monitoring torque thresholds, storing peak steering angles within specific torque ranges, and correcting for deformation to enhance precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If maximum and minimum steering angle values are used to determine the entire steering angle range, then the detection method is simple, but detection precision is reduced due to mechanism twist or backlash

Engineering Contradiction:
Improvedetection method complexityVSAvoidrack end position detection precision
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical detection method (using maximum/minimum steering angle values directly) with an electrical detection method (monitoring torque sensor signals). By detecting the torque value changes during steering operations and identifying when torque exceeds predetermined thresholds, the system achieves more precise rack end position detection without being affected by mechanism twist or backlash, thereby resolving the contradiction between simplicity and precision.

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

2Ease of operation

If center position of rack is calculated from left and right end positions, then reference point can be obtained, but precision is affected by rack end position detection accuracy

Engineering Contradiction:
Improvereference point calculationVSAvoidreference point precision
Core Design Contradiction:
Ease of operationVSMeasurement precision

Solution Approach 1:

The patent implements a feedback mechanism where the torque sensor continuously monitors the torque values during steering operations. When the torque value exceeds a predetermined threshold, the system identifies this as the rack end position and provides feedback to the control unit. This feedback-based detection method ensures high precision in rack end position detection, which directly improves the precision of subsequent reference point calculations derived from these end positions.

Inventive Principle:
Principle #23Feedback

3Ease of operation

If standard detection methods are used, then detection process is straightforward, but nonstandard rack installations cannot be detected

Engineering Contradiction:
Improvedetection processVSAvoidnonstandard installation detection
Core Design Contradiction:
Ease of operationVSAdaptability or versatility

Solution Approach 1:

The patent employs parameter changes by establishing predetermined torque thresholds that define the detection criteria for rack end positions. By monitoring whether the actual torque values exceed these predetermined parameters, the system can detect not only standard installations but also nonstandard rack installations. If the detected end positions fall outside expected ranges or patterns, the system identifies the nonstandard installation condition, thereby achieving both operational simplicity and adaptability to various installation types.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentEP4086148B1Device and method for detecting end positions of turning device, and program
Publication Date: 2025.08.20 NSK LTD
  • EP4086148B1 patent drawingFigure 1
  • EP4086148B1 patent drawingFigure 2
  • EP4086148B1 patent drawingFigure 3

AI summary

In a detection method for detecting an end position of a mechanism portion of a turning device, detection of a limit position of a steering angle in a direction of a torque value is started when the torque value of the mechanism portion loaded by at least one of a drive force from an actuator and steering torque to the mechanism portion exceeds a first threshold. The limit position continues to be detected by storing a peak value of the steering angle in the mechanism portion as the limit position while the torque value of the mechanism portion is between the first threshold and a second threshold. The stored limit position is regarded as the end position indicated by the torque value when the torque value of the mechanism portion exceeds the second threshold.