Engineering

Steering Systems Development

Engineering Precision and Control.

As an independent service provider, we take your mobility to the next level. With our engineering expertise in conventional steering systems and pioneering Steer-by-Wire solutions we set new standards while always remaining focused on your KPIs.

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The future of mobility and technology is undergoing a huge transformation – as is the way how we steer vehicles. While mechanical steering systems with electrical assistance remain present today, the focus is shifting toward a digital future with Steer-by-Wire systems, eliminating the need for a mechanical link between the steering wheel and the steering transmission.

At AVL, we develop and optimize steering systems and functions for all markets. Our focus is on innovative digital solutions and the precise design of steering feel through the use of software, sensors, and actuators. In addition, we offer seamless integration of mechanical, electromechanical, and functional components.

By using simulation-based development methods, we maximize frontloading and drive efficient development. From the initial concepts onward, we support you in making decisions right – whether for passenger cars or commercial vehicle development.

The Challenges

Integrating an innovative steering system into an existing vehicle architecture is a complex challenge that demands extensive expertise and new safety concepts.

Permanent Focus on the Overall System

Successful development starts at the level of the overall vehicle. A top-down approach is essential for ensuring that all components work together harmoniously. If development starts at software level, you run the risk of losing sight of the overall system.

Functional Safety (FS)

What happens if components of a Steer-by-Wire system fail?
How can I ensure the steering still functions? These questions are central to developing a functional safety concept and designing a redundant steering system.

Complex Electronics and Software

Flawless functioning of the steering system requires thorough validation of software, components, and the integrated network. This process is time-consuming and requires in-depth system knowledge to ensure maximum reliability.

Optimal Steering Feel

How can a natural steering feel be created for Steer-by-Wire systems despite the lack of a mechanical connection? The answer lies in functions that provide drivers with precise feedback on wheel movements and forces.

These functions are the result of extensive development and need to be designed, tested, and calibrated to achieve the desired effect.

Our Approach

Our benchmarking data is the basis for developing the optimal steering feel. We analyze existing vehicles and steering systems to record the desired parameters and develop your system with a clear focus on these targets.

First, we define test cases in which a good steering feel is noticeable. Using state-of-the-art equipment, we perform the specified driving maneuvers, gather extensive data, and create a precise steering reference model.

This theoretical model simulates various characteristics across the entire steering system and provides crucial inputs for our systems engineering. The software model reflects all relevant parameters, such as friction and damping, enabling for a high level of maturity early in the development process.

In our functional architecture concept, we determine the required functions and the related system layout to achieve the optimal target function.

Benefits

Our continuous methodology and systems engineering approach makes development more efficient, faster, and more economical.

Targeted Frontloading

Utilizing the latest, virtual development tools combined with our continuous methodology allows you to make informed decisions early on and reduce development time.

Very High Level of Maturity

We achieve a very high level of maturity in the virtual development phase. This enables us to develop functionalities and accompanying safety concepts in a safe environment without hardware prototypes.

Driver-in-the-Loop: Focus on the Driver

To validate the steering system as early on as possible, we use three different driving simulators. This environment enables the steering feel to be optimized and the software to be pre-calibrated for future integration, which saves development time.

Objectification of Steering Feel with AVL-DRIVE^TM

Our proven development tool, AVL-DRIVE™, provides a precise and objective assessment of steering feel, both in real-world and virtual environments. This enables us to consistently monitor the desired steering and driving characteristics, set specific development and improvement targets, and validate them effectively.

Steering Reference Model

The physical steering model generated using AVL-DRIVE^TM enables us to precisely determine the target steering characteristics of your steering system and serves as a basis for using systems engineering for efficient system development.

Customizable Whitebox-Software

We also offer whitebox-software on request. You have the option of refining and modifying this software in collaboration with us or independently.

Systems Engineering Without a Physical Prototype

Our Driver-in-the-Loop (DiL) approach enables precise development of your steering system according to standard specifications, using a driving simulator in place of a physical vehicle. Individual components are tested on a dedicated Hardware-in-the-Loop (HiL) testbed. This allows us to virtually replicate the entire vehicle and optimize existing systems – whether at the component level or within the software.

Comprehensive FuSa-Services

Functional safety – simple, secure, and results-driven: Our services cover every aspect of functional safety, from conceptual and series development to system and vehicle validation.

Concept development

Analysis of hazards and risks (ASIL classification)
Failure mode and effect analysis, fault tree analysis
Prototype safety concepts
Development of functional safety concepts
Simulation-based construction support
Safety/supplier management

Systems engineering

Technical safety concept
Modeling, draft, and pre-calibration of safety mechanisms

Safety tests

Test planning/management
Analysis of fleet data