Comsol Case Studies Revving up Electrohydraulic Power Steering with Virtual Prototyping

	Revving up Electrohydraulic Power Steering with Virtual Prototyping Comsol

Revving up Electrohydraulic Power Steering with Virtual Prototyping

Comsol

Technology Category	Analytics & Modeling - Predictive Analytics Analytics & Modeling - Real Time Analytics Application Infrastructure & Middleware - Data Visualization
Applicable Industries	Automotive Equipment & Machinery
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Predictive Maintenance Machine Condition Monitoring Virtual Prototyping & Product Testing
Services	Software Design & Engineering Services System Integration Testing & Certification
Challenge	Designing an electrohydraulic power steering (EHPS) system involves managing numerous interrelated components, where minor adjustments can significantly impact the system's function, efficiency, and reliability. The complexity of the system, which includes an electronic control unit (ECU), torque sensor, valve, and pipe system, requires a detailed understanding of how each part interacts. Traditional validation and physical testing methods are expensive and time-consuming, often taking up to six months. This slow process is not conducive to the fast-paced design cycles required in the automotive industry. Therefore, there is a need for a more efficient method to refine and optimize EHPS designs before moving to physical testing. Read More
About Customer	FZB Technology, based in Plymouth, MI, specializes in research and development for the automotive market. The company focuses on developing advanced automotive components such as motors, sensors, keyless RFID ignition systems, and electrohydraulic power steering (EHPS) systems. FZB Technology employs a team of skilled engineers who frequently use advanced simulation tools to model and refine their designs. The company collaborates with major automotive manufacturers, including Chrysler, to ensure their products meet industry standards and requirements. FZB Technology is committed to innovation and efficiency, leveraging cutting-edge technology to stay ahead in the competitive automotive sector. Read More
Solution	FZB Technology employs multiphysics simulation using COMSOL Multiphysics® software to model and refine their EHPS designs. This approach allows them to understand the behavior of the system's components and move closer to a final design before physical testing. The team models major components such as the ECU, motor, fluid reservoir, and helical gear pump, performing both individual and multiphysics analyses. These simulations help solve issues related to thermal performance, dynamic motion control, fluid delivery, and noise, vibration, and harshness (NVH). By using simulation, FZB can expedite the design refinement process, reducing the time and cost associated with physical testing. The team also uses specialized software like PumpLinx® for fluid efficiency analysis and SOLIDWORKS® for geometry updates. This integrated approach enables them to make significant design improvements and meet automotive requirements more efficiently. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Analytics & Modeling - Real Time Analytics

Application Infrastructure & Middleware - Data Visualization

Applicable Industries

Automotive

Equipment & Machinery

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Predictive Maintenance

Machine Condition Monitoring

Virtual Prototyping & Product Testing

Services

Software Design & Engineering Services

System Integration

Testing & Certification

Challenge

Designing an electrohydraulic power steering (EHPS) system involves managing numerous interrelated components, where minor adjustments can significantly impact the system's function, efficiency, and reliability. The complexity of the system, which includes an electronic control unit (ECU), torque sensor, valve, and pipe system, requires a detailed understanding of how each part interacts. Traditional validation and physical testing methods are expensive and time-consuming, often taking up to six months. This slow process is not conducive to the fast-paced design cycles required in the automotive industry. Therefore, there is a need for a more efficient method to refine and optimize EHPS designs before moving to physical testing.

About Customer

FZB Technology, based in Plymouth, MI, specializes in research and development for the automotive market. The company focuses on developing advanced automotive components such as motors, sensors, keyless RFID ignition systems, and electrohydraulic power steering (EHPS) systems. FZB Technology employs a team of skilled engineers who frequently use advanced simulation tools to model and refine their designs. The company collaborates with major automotive manufacturers, including Chrysler, to ensure their products meet industry standards and requirements. FZB Technology is committed to innovation and efficiency, leveraging cutting-edge technology to stay ahead in the competitive automotive sector.

Solution

FZB Technology employs multiphysics simulation using COMSOL Multiphysics® software to model and refine their EHPS designs. This approach allows them to understand the behavior of the system's components and move closer to a final design before physical testing. The team models major components such as the ECU, motor, fluid reservoir, and helical gear pump, performing both individual and multiphysics analyses. These simulations help solve issues related to thermal performance, dynamic motion control, fluid delivery, and noise, vibration, and harshness (NVH). By using simulation, FZB can expedite the design refinement process, reducing the time and cost associated with physical testing. The team also uses specialized software like PumpLinx® for fluid efficiency analysis and SOLIDWORKS® for geometry updates. This integrated approach enables them to make significant design improvements and meet automotive requirements more efficiently.

Impact #1	The use of multiphysics simulation allows FZB Technology to expedite the design refinement process, significantly reducing the time required for physical testing.
Impact #2	By modeling thermal, mechanical, fluid, and electromagnetic phenomena, the team can quickly identify and solve issues related to thermal performance, dynamic motion control, and fluid delivery.
Impact #3	The integrated approach using COMSOL Multiphysics®, PumpLinx®, and SOLIDWORKS® enables the team to make significant design improvements and meet automotive requirements more efficiently.

Impact #1

The use of multiphysics simulation allows FZB Technology to expedite the design refinement process, significantly reducing the time required for physical testing.

Impact #2

By modeling thermal, mechanical, fluid, and electromagnetic phenomena, the team can quickly identify and solve issues related to thermal performance, dynamic motion control, and fluid delivery.

Impact #3

The integrated approach using COMSOL Multiphysics®, PumpLinx®, and SOLIDWORKS® enables the team to make significant design improvements and meet automotive requirements more efficiently.

Benefit #1	Physical testing time reduced from six months to a shorter period due to the use of simulation.
Benefit #2	Significant cost savings achieved by reducing the need for extensive physical testing.
Benefit #3	Improved design cycle speed, enabling faster time-to-market for EHPS systems.

Benefit #1

Physical testing time reduced from six months to a shorter period due to the use of simulation.

Benefit #2

Significant cost savings achieved by reducing the need for extensive physical testing.

Benefit #3

Improved design cycle speed, enabling faster time-to-market for EHPS systems.

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Overview

Revving up Electrohydraulic Power Steering with Virtual Prototyping

Operational Impact

Quantitative Benefit