Psa System Spec 01452 13 00009 BMPV 1v5 Eps Technical Specification

Reference:
01452_13_00009
RESEARCH AND DEVELOPMENT DEPARTMENT
Doc info ref : 01452_13_00009
DRD/DCTC/ICDV/AFDH/AFD2
Technical Specification
Electric Power Steering for BMPV / 1V5
This Technical Specification (TS) is a document which gathers the specified technical requirements, consistent
with all the stakeholders’ inputs for the considered product. It expresses what the product shall do, and not how it
shall do it. The TS relies on the STS and adapts it to the perimeter of the vehicle or component project.
Write Check Approve

Name: Fabien LAVILLENIE Name: Benoit BERTHE Name: Robert REGNARD
Unit: DCTC/ICDV/AFDH/AFD2 Unit: DCTC/ICDV/AFDH/AFD1 Department: DCTC/ICDV/AFDH/AFD2
Date: Signature: Date : Signature: Date: Signature:
Check Check Approve

Name: Name: Philippe CARTIER Name: Xavier CLEMENT
Unit: Unit: DSEE/CIEE/IECT/CTC Department: DCTC/ICDV/AFDH
Date: Signature: Date: Signature: Date: Signature:
Write Check Approve

Name: Name: Xavier CHIRON Name: Jean-Robert CASANO
Unit: Unit: Department: DCTC/ICDV/AFDH
DCTC/ICDV/CLDR/SDV/MCDE
Date: Signature: Date: Signature: Date: Signature:
REFERENCE IND PROJECT PAGE

Technical Specification EPS
01452_13_00009 BMPV/1V5 1/178
CE DOCUMENT EST LA PROPRIETE DU GROUPE PSA PEUGEOT CITROEN ET NE PEUT ETRE REPRODUIT OU COMMUNIQUE SANS SON AUTORISATION
PSA PEUGEOT CITROËN
REVISIONS HISTORY
Index Date Modifications type
OR V1.0 14/01/2013 Creation
V2.0 Removal of temperature values, replacement by acronyms : TminHF, TminEF,

Tmoy, TmaxEF, TmaxHF.
Removal of schema in some test sheet.
Page 7 : Add of Hollow rack, protection for outer ball joint thread and male
hexagonal interface for outer ball joint /knuckle interface and high temperature
environment option
Page 10 : Add of Service function for citypark SCP06 and SCP09
Page 10 : removal of ISO Standard 7637 EMC
Page 12 : Add of CTF list document reference, modification of reference for
document [A1118] and BMPV_1V5_EPS_Diagnostic_matrix [A006]
Page 14 : New index for B25 1140 H instead of G, New index for B20 0250 K
instead of J
Page 15 : New index for B51 1110 N instead of M
Page 15 : Removal of B63 0020 replace by ISO 1629.
Page 15 : Add standard B71 600 for fluid and material compatibility
Page 15 : New index for D24 1312 E instead of D
Page 19 : Modification of voltage range
Page 19 : Modification of value of mechanical withstand at rack end stop
BMPV/1V5_EPS_TS_SYSTEM_008 : Gear ratio, precision on value for 1V5
and for variable gear ratio.
BMPV/1V5_EPS_TS_SYSTEM_009 : Modification of rack travel expected for
1V5
BMPV/1V5_EPS_TS_SYSTEM_010 : Modification of the Height of mechanism
requirement
BMPV/1V5_EPS_TS_SYSTEM_014 : add objective after F3 load
BMPV/1V5_EPS_TS_SYSTEM_018 : modification and declination of friction
effort.
BMPV/1V5_EPS_TS_SYSTEM_025 : add reference to [A006] specification
BMPV/1V5_EPS_TS_SYSTEM_027 : precision on torque to apply for ripple
(on center torque)
BMPV/1V5_EPS_TS_SYSTEM_030 : Add of the number of steering wheel
speed point.
BMPV/1V5_EPS_TS_SYSTEM_186 : Assistance – Steering wheel dynamic
limitation added
BMPV/1V5_EPS_TS_SYSTEM_187 : Control functions and control features
availability added
BMPV/1V5_EPS_TS_SYSTEM_032 : add the total number of calibration
expected.
BMPV/1V5_EPS_TS_SYSTEM_042 : add reference to B20 0200 and
modification of B20 0250 table report [A3059] instead of [A3052]
BMPV/1V5_EPS_TS_SYSTEM_044 : Replacement of the norm D47 1100 by
01452_13_00009 BMPV/1V5 2/178
the D10 5010 and add reference to B62 0300 for ozone concentration
BMPV/1V5_EPS_TS_SYSTEM_046 : Removal of EMC ISO standard and add
reference to HW specification
BMPV/1V5_EPS_TS_SYSTEM_047 : Add IR04 test and reference to HW
specification
BMPV/1V5_EPS_TS_SYSTEM_049 : Add High pressure water tightness
Index and applicable test sequence
BMPV/1V5_EPS_TS_SYSTEM_050 : add applicable test sequence
BMPV/1V5_EPS_TS_SYSTEM_054 : removal of the requirement included
inside BMPV/1V5_EPS_TS_SYSTEM_045
BMPV/1V5_EPS_TS_SYSTEM_055 : shall respect Requirement 049 after the
test.
BMPV/1V5_EPS_TS_SYSTEM_056 : Add test sequence applicable
BMPV/1V5_EPS_TS_SYSTEM_057 : Optimization of torque requirement
BMPV/1V5_EPS_TS_SYSTEM_061 to 064 : Modification of maximum voltage
24V instead of 18V, add test sequence applicable
BMPV/1V5_EPS_TS_SYSTEM_065 : add applicable test sequence
BMPV/1V5_EPS_TS_SYSTEM_070 : modification of Tg requirement on PCB
BMPV/1V5_EPS_TS_SYSTEM_085 : modification of the minimum voltage to
11,3 V instead of 10,5 V.
BMPV/1V5_EPS_TS_SYSTEM_087 : modification of the minimum voltage to
11,3 V instead 10,5V.
BMPV/1V5_EPS_TS_SYSTEM_089/088 : modification of requirement number
for LKA (89 instead of 88) and multimode (90 instead of 89)
BMPV/1V5_EPS_TS_SYSTEM_090 : add of tuneable parameter for
multimode function.
BMPV/1V5_EPS_TS_SYSTEM_091 : add reference to test sequence A
BMPV/1V5_EPS_TS_SYSTEM_092 : Modification of Energy target
BMPV/1V5_EPS_TS_SYSTEM_102 : modification of grii Noise target
BMPV/1V5_EPS_TS_SYSTEM_188 : New requirement for in-car subjective
evaluation.
BMPV/1V5_EPS_TS_SYSTEM_103 : Add reference to safety and
dependability specification
BMPV/1V5_EPS_TS_SYSTEM_105 : Add reference to [A006] specification
BMPV/1V5_EPS_TS_SYSTEM_114 : Add reference to Test sheet N°79 and
functional drawing
§5.4.1 : add of Tmin HF, EF, Tmax HF, EF and Tmoy for refrence quote and
option 3.
BMPV/1V5_EPS_TS_SYSTEM_118 : Add Weight objective for 1V5
BMPV/1V5_EPS_TS_SYSTEM_0138 : add of reference [A006] specification
BMPV/1V5_EPS_TS_SYSTEM_0148 : add reference to standard B20 1315
and B20 1415
BMPV/1V5_EPS_TS_SYSTEM_160 : add reference to test sequence
BMPV/1V5_EPS_TS_SYSTEM_164 : Replacement of D45 1291 by D10 5010
BMPV/1V5_EPS_TS_SYSTEM_169 and 170 : replacement of D47 1053 by
D10 5010
BMPV/1V5_EPS_TS_SYSTEM_168 : add reference to standard B71 6000.
BMPV/1V5_EPS_TS_SYSTEM_171 : add reference to test sequence
BMPV/1V5_EPS_TS_SYSTEM_186 : modification on test sequence A
(thermal durability cycle) and add 2 new sequence (H and I).
REFERENCE IND PROJET PAGE

01452_13_00009 BMPV / 1V5 3/178
Deletion of test sheet N°04 : merged with test sheet N°03
Test sheet N°03 : modification of the expected results and test to be done on
this test sheet.
Test sheet N°04 : maximum voltage modification 24 instead of 20V
Test sheet N°05 : removal of temperature note.
Test sheet N°06 : modification of soaking temperature
Test sheet N°14 : Modification of the test condition for the grii noise test.
Test sheet N°20 : Correction on over torque for Fp2 situation (100Nm instead
of 10 Nm), modification of effort value.
Test sheet N°21 : Modification on test sequence for CRD test.
Test sheet N°30 : Modification of effort value.
Test sheet N°33 : Modification of effort value.
Test sheet N°40 : modification of requirement reference 092 instead of 082
Test sheet N°50 : reference to Test sheet 70 instead of 69.
Test sheet N°51 : modification of fluid reference (reference to B71 6000) and
add of harness test compatibility.
Test sheet N°58 : Removal of time requirement and link added with the
BMPV/1V5_EPS_TS_SYSTEM_025 requirement, add of 2 situations to be
tested.
Test sheet N°62 : Add of component to follow during the tests.
Test sheet N°63 : Modification of cycle Number 500 instead of 600
Test sheet N°70 : modification of reference specification ([A003] instead of
[A002].
Test sheet N°71 : Modification of EPS state expected during the test.
Test sheet N°72 : correction of test sheet for test method
Test sheet N°79 : add note for fluid compatibility
Test sheet N°90 : add testing condition (load)
Page 168 : Test sheet N°91 : add testing condition (load)
Test sheet N°99 : add testing condition (load)
Annexe 1 unusual effort : Rename of Reference and option, add of VC1, VC2
effort value
Removal of reference to Test sheet 42.

01452_13_00009 BMPV / 1V5 4/178
CONTENT
1 OBJECT 6
2 FIELD OF APPLICATION 7
2.1 GENERAL DESCRIPTION OF THE SYSTEM 7
2.1.1 Diversity 7
2.1.2 System limits 7
2.1.3 Situations of life 7
2.1.4 Context of use for the product 8
3 QUOTED DOCUMENTS 10
3.1 REFERENCED DOCUMENTS 10
3.1.1 PSA standards 10
3.1.2 Vehicle Functional Requirements 10
3.1.3 French and international standards 10
3.2 APPLICABLE DOCUMENTS 11
3.2.1 Functional Requirements, Component Technical Specifications, product interfaces, terms of
management and quality insurance 11
3.2.2 European guidelines 12
3.2.3 Functional and interface drawings 12
3.2.4 French and international standards 13
3.2.5 PSA standards 13
3.2.6 PSA analysis procedures 15
4 TERMINOLOGY 16
4.1 ACRONYMS 17
5 REQUIREMENTS 18
5.1 FUNCTIONAL REQUIREMENTS 18
5.1.1 Mechanism 18
Kinematic integrity 18
Mechanical resistance 20
Frictions 21
Steering flexibility 22
5.1.2 Angle of the steering wheel 22
5.1.3 Assistance 22
5.2 PERFORMANCE REQUIREMENTS 27
5.2.1 List of the constraint functions 27
5.2.2 Compliance with standards 27
5.2.3 Interface with other systems 27
5.2.4 Constraints with the external environment 28
5.2.5 Performances 33
Performances related to the steering wheel speed 33
Evolution of the assistance torque related to the rack travel 34
Performances According to temperature and supply voltage 35
Steering wheel torque during an avoidance maneuver 39
Performance of the thermal sizing 39
High speed parking maneuver 41
Centering and hysteresis 41
Low speed cornering 42
5.2.6 Road feedback 42
Force stress 42
Displacement stress 44
5.2.7 Inertia feeling 45
5.2.8 Additional requirements of STTa function 45
5.2.9 CityPark function requirements 46
Power assistance need 46
CityPark angle control Performance 46
Thermal Sizing 47
Durability 48
5.2.10 Lane Keeping Assist 48
5.2.11 Multi mode assistance 48
5.2.12 Mechanical resistance 49
5.2.13 Assembly 50
01452_13_00009 BMPV / 1V5 5/178
5.2.14 Quality 51
5.2.15 Acoustic level 51
Product acoustic radiation 51
Blocking Efforts 52
EPS system blocking Efforts with a « Back-Lash » excitation type and rack end system blocking efforts 52
Grii Noise 53
5.2.16 Diagnostics and calibration 54
5.2.17 Incident/Accident 54
5.2.18 Electric consumption 55
5.2.19 Ground clearance 55
5.3 EXTERNAL INTERFACE REQUIREMENTS 56
5.4 OPERATIONAL REQUIREMENTS 57
5.4.1 Mission profile 57
5.4.2 Ergonomics and human factors 58
5.4.3 Product quality 59
Appearance 59
Quality objectives 59
5.4.4 Protection against malicious intent 59
5.4.5 System resources 59
5.4.6 Documentary requirements 59
5.4.7 Mass production evolution 59
5.5 CONSTRAINTS REQUIREMENTS 60
5.5.1 Regulatory and consumerism 60
5.5.2 Weight and other physical characteristics 60
5.5.3 Design and production 60
Studies and/or imposed solutions 60
Product marking 60
5.5.4 Traceability and configuration monitoring 61
Product Identification 61
5.5.5 Transportability and conditioning 62
Transportation means and conditioning 62
Supply approval 63
5.5.6 Flexibility and extension 63
5.5.7 Maintenability 63
5.5.8 Materials 64
Service removal 64
Plastic Materials and rubber 64
Metalic Materials 70
5.6 INTEGRATION AND VALIDATION REQUIREMENTS 73
5.6.1 Validation drawing 73
5.6.2 Development sessions 73
5.6.3 Validation tests 73
General Information 73
Test Conditions 73
List 74
5.6.4 Test sequence 78
5.6.5 Descriptive sheets 79
N°01: Assistance law measurement 79
N°02: Assist variation 81
N°03: Performances versus steering wheel speed, Ambient Temperature and power supply voltage 82
N°05: Assist Performance related to the rack travel 85
N°06: Thermal protection Performances 86
N°07: Mechanical friction 90
N°08: Weight 93
N°09: Gear ratio reduction 94
N°10: Tie rod tilting and rotational torque 95
N°11: Acoustic level 97
N°12: Assembly effort 100
N°13: Break-away force 101
N°14: Grii noise test 102
N°20: Mixed durability Test (mechanical resistance) 103
01452_13_00009 BMPV / 1V5 6/178
N° 21: CRD durability (acoustic behavior) 107
N°22: Resistance to vibration 110
N°30: Fastening tabs durability on subframe 112
N°33: Tie rod fatigue 114
N°41: Impact test on mechanism rack end stop position 118
N°43: Resistance to exceptional efforts 120
N°50: Accelerated Corrosion 121
N°51: Resistance to chemical and atmospheric agents (B21 7130/CL25) 128
N°52: Corrosive thermal atmosphere 130
N°54: Dynamic performances 1 133
N°55: Dynamic performances 2 134
N°56: Centering and steering wheel return 136
N°57: Steering stiffness 138
N°58: initialization time for the assistance 140
N°59: assistance law hysteresis 142
N°60: Information feedback – displacement load 144
N°61: Operation after storage (B21 7130/CL01) 145
N°62: Self-heating measurement (B21 7130/CL06) 146
N°63: Ageing by air/air thermal shocks (B21 7130/CL07) 147
N°64: Thermal cycles durability (B21 7130/CL08) 148
N°65: Endurance to activations (B21 7130/CL09) and to STT voltage supply situations (IC12) 150
N°66: Endurance to high temperature (B21 7130/CL10) 152
N°67: Determination of operating limits at a temperature (B21 7130/CL11) 154
N°68: Protection of the envelops against solid bodies (IP5X) (B21 7130/CL13A Category 1) 156
N°69: Protection of the envelops against liquids penetration (IPX3) (B21 7130/CL13B) 157
N°70: Vacuum immersion (IP68) (B21 7130/CL14) 158
N°71: Thermal shocks with iced water (B21 7130/CL15B) 159
N°72: High pressure wash (IPX9K) (B21 7130/CL16) 160
N°75: Ball drop (B21 7120/M3.1) 161
N°78: Test on internal connection elements (B21 7120/M1.2) 162
N°79: Harness validation (B25 1140) 163
N°80: Plastic material ageing related to climatic cycle (D47 1309) 164
N°90: Swept sine parking maneuver 165
N°91: Steering wheel torque peak during avoidance maneuver 166
No.99: Electric consumption 167
N°100: Performance of citypark angle control 169
N°101: EPS durability performance related to the citypark function availability 171
N°102: Mixed durability test for citypark 173
N°110: Steering wheel torque in case of short cuts (Phase/GND, Phase/+BAT, between Phases) 176
6 APPENDIXES 180
6.1 APPENDIX 1: UNUSUAL EFFORTS 180
6.1.1 Usual life situations: 180
6.1.2 Maximal efforts (curbpush away) 180
6.1.3 Wheel Impact Stress 180
6.2 APPENDIX 2: LIST OF THE QUOTED PSA STANDARDS 186
6.3 APPENDIX 3: ANALYSIS PROCEDURES 188
6.3.1 List of deliverables 189

01452_13_00009 BMPV / 1V5 7/178
1 OBJECT
The purpose of this document is to complete, by the PSA group specifications, the functions, rules, and regulations
regarding the supplier’s component.
This document has a contract value only when combined with the supplier assignment letter delivered by the
Purchase Department.
This document applies to:

 the New BVH1 module.
 The Electric Power Steering (EPS) component which will be called later, « the product ».
The purpose of this document is to:
Formalize functional requirements,
Define technical specifications of the product.
This Technical Specification (TS) describes:
How the product shall work,
The situations of life applicable for the product,
Expected performances of the product.
2 FIELD OF APPLICATION
2.1 GENERAL DESCRIPTION OF THE SYSTEM
2.1.1 Diversity
 BMPV/1V5_EPS_TS_SYSTEM_01: Diversity
The supplier shall propose at minima one LHD and one RHD system. The supplier could propose a
declination of the electric motor.
AEE2004 Merco AEE2010 Evo

LHD x X
RHD X
Option 1 : Hollow rack to be quoted for the whole volume of BVH1V5 Europe
Option 2 : Protection on Outer ball joint thread for Amlat and China volume
Option 3 : High temperature environment (1V5 only)
Option 4 : Male hexagonal interface for Tie rod to vehicle knuckle interface (on complete volume)
Option A : high chassis effort on BMPV
Option B : 73 mm rack travel on BMPV
Option A+B : combination of option A and B
2.1.2 System limits

 BMPV/1V5_EPS_TS_SYSTEM_002: System limits
The considered product includes:
 The complete steering mechanism, including tie rods and fasteners on vehicle as defined in the functional
drawings [A4010] (with studs, washers and inner/outer ball joint),
 The ECU (integrated) and the related sensors,

01452_13_00009 BMPV / 1V5 8/178
 The power and signal harness as defined in the functional drawings [A4010]
o Position and orientation of the output point.
o Harness lengths from this point.
For the product delivery at PSA manufacturing plants, electrical harness (power and signal) should be
clamped securely on the mechanism. All devices necessary for flanging shall be integrated into the
perimeter and detailed by the supplier during the tender for bill.
 The electric actuator,
 Protection parts for sensitive areas,
o Connections (dust, humidity…).
o All other areas considered useful by the supplier (protection for threads during transport, …)
 A system to keep harness rigidly up to the output point of the supply.
 A system of clearance compensation on the main mechanical interfaces (for example: assistance reducer,
pinion / rack, steering rack guide, according to the selected architecture).
The product under consideration does not include:
 Washers and nuts under subframe,
 Nuts on knuckle,
 Dash panel seal.
2.1.3 Situations of life

The considered product is involved in the following situations of life:
 Life before vehicle sale
 Logistic / Transport of the product from supplier to PSA manufacturing plants
 Incoming inspection
 Product storage before assembly
 Transfer of the system from storage area to manufacturing lines
 Assembly on manufacturing lines
 First power On and First EPS configuration (downloading of the calibration file)
 Inspection at the end of assembly line
 Vehicle storage, vehicle immobilization during a long-term on a PSA storage area
 Vehicle transport by truck, boat or train, customer delivery
 Use
 Vehicle at standstill:
o Thermal Engine cranking
o Thermal Engine running
o Thermal Engine stopped (STT)
o Thermal Engine cut stalled (ignition cut or not)
o Thermal Engine restart (STT)
o Parking maneuver (including curb push away)
 Driving situation:
o Thermal Engine cranking
o Thermal Engine running
01452_13_00009 BMPV / 1V5 9/178
o Thermal Engine stopped (STT)
o Thermal Engine cut stalled (ignition cut or not)
o Thermal Engine restart (STT)
o Cruising (city, road, highway, mountain)
o Parking maneuver
o Avoidance maneuver
o Acceleration/deceleration
 Incidents/Accidents
 Road accident
 Curb push away shocks
 Repair/ Maintenance / Technical Inspection
 Towage
 Repair or inspection (by a mechanic of the network OR by the customer)
 Storage
 Test during the Technical Inspection
 Destruction/Recycling
2.1.4 Context of use for the product

 Drive the vehicle:
o Allow the driver to steer the vehicle
o Allow the driver to feel the road profile
o Filter road disturbances
o Automatically correct the steering in straight line even at low vehicle speed
o Allow driver to do avoidance maneuver
o Provide directional stability (especially in straight line)
 Assist the steering: Provide a variable assistance according to internal or vehicle information: thermal
engine status, vehicle speed, steering wheel torque, steering wheel angle and steering wheel speed.
In the vehicle tree structure, the product position is placed as follow:
Vehicle
Chassis subsystem
Steering Unit
Electric Power
Steering Mechanism
Component
The studied product contributes to following functions (FS: Service Function, FC: Constraint Function)
Service Functions:
FS 01: Transmit in both directions (input shaft  knuckle) the 2 data angle and torque
FS 01.1: Allow the driver to steer the vehicle;

01452_13_00009 BMPV / 1V5 10/178
FS 01.2: Provide variable assistance to the driver, according to the vehicle life situation;
FS 01.3: Drive the steering wheel for Citypark function : Allow the achievement of SCP06 and SCP09
functions :
SCP06 : Assist the driver to enter in a parking place by automated maneuver
SCP09 : Assist the driver to exit a parking place by automated maneuver
Constraint Functions:
FC 01: Comply with standards.

FC 02: Signal the current EPS state of working to other systems in the vehicle
FC 03: Isolate passenger compartment.
FC 04: Respect and withstand Components in mechanical interface.
FC 05: Respect and withstand environment.
FC 06: Respect and withstand surrounding Components.
FC 07: Respect and withstand test bench.
FC 08: Adapt to energy sources.
FC 09: Respect and withstand the driver.
FC 10: Communicate with Components in EE interface.
FC 11: Withstand constraints generated by transport facilities.
FC 12: Respect and withstand operator.
FC 13: Respect and withstand shipping package.
FC 14: Adapt / withstand tool equipment.
FC 15: Preserve physical integrity of passengers, driver and external persons.
FC 16: Integrate into the valorization streams.
FC 17: Respect the ground clearance (if the lowest point belongs to the system).
FC 18: Adapt to and withstand inspection facilities (including development and diagnostic tools).
3 QUOTED DOCUMENTS
3.1 REFERENCED DOCUMENTS
3.1.1 PSA standards
SPR
Link Reference Document title
access
B94 1100
[R1070] Chargement des trains – Eléments de calcul. No
Ind D (02/2008)
Q_185130-01 Codification des informations de traçabilité par lien unitaire pour
[R1080] No
V001 (05/2003) CORVET.
Q_185132 Référentiel traçabilité des composants électronique
[R1090] No
V000 (03/2007) interrogeables.
B13 3116
[R1100] Vissage – Expression des paramètres sur les documents No
Ind M (12/2011)
[R1120] R15 4701 Ensemble direction – boitiers électroniques – CEM R Yes

01452_13_00009 BMPV / 1V5 11/178
Ind B (06/2010)
R15 4152
[R1130] Ensemble de direction – Mécanisme R Yes
Ind OR (08/2006)
3.1.2 Vehicle Functional Requirements

Link Reference Document title SPR access
ST Véhicule - Diriger le Véhicule et Assister la No

[R3010] DMFV_SYFA06_1014
Direction_V1
3.1.3 French and international standards

Document designation SPR access
Mark Reference
Marquages et déclarations environnementaux - Auto No
[R4011] ISO 14021
déclarations environnementales
Caoutchouc, vulcanisé ou thermoplastique, No
[R4012] ISO 14309
détermination du volume et/ou de la résistivité
Caoutchouc, vulcanise ou thermoplastique No
[R4013] ISO 48
détermination de la dureté
3.2 APPLICABLE DOCUMENTS

3.2.1 Functional Requirements, Component Technical Specifications,
product interfaces, terms of management and quality insurance
SPR
Link Reference Document title
access
[A002] 01452_12_00134 ST Diag & DTC DAE Yes
[A003] 01552_12_03566 ST Hardware EPS Yes
[A004] 01552_12_10540 Dossier de consultation software EPS Yes

ILSI_AFDH06_0763 Synthèse des spécifications de maillage choc des
[A005] Yes
(Version 1 du 10/2006) DAE.
[A006] 01452_13_00094 BMPV_1V5_EPS_Diagnostic_matrix Yes
[A1020] DA_MQF05_0015_EX_En_V005 Plan Type PCP Yes
[A1021] DA_MQF05_0002_EX_En_V006 Inspection report template Yes
[A1022] DTI_DQI08_0020 Mass production evolution management Yes
[A1023] Standard management of a Supplier request for a Yes

01372_11_00987
mass production evolution
CPPR (Clauses Particulières et Planning des
[A1030] 01598_13_00770 Yes
Résultats)
CPPR (clauses particulières et planning de
[A1031] 01552_12_10720 Yes
résultats) SW
[A1082] Tbd Xxx EPS - Durability CRD profile Yes
[A1100] 01446_12_00049 Dossier d'exigences Diagnosticabilité Yes

[A1101] AEEV_IAEE07_0061 Guide d’utilisation du tableau de synthèse Yes
01452_13_00009 BMPV / 1V5 12/178
diagnosticabilité
[A1102] 01446_12_00050 Tableau de Synthèse du Diagnostique Yes
[A1110] Tbd Objectifs qualité EPS Yes
[A1111] 01452_13_00063 EPS Specification rack load vs rack travel Yes

EPS Specification - Parking maneuver for thermal
[A1112] 01452_13_00063 Yes
protection
EPS Specification - Elementary maneuver for
[A1113] 01452_13_00063 Yes
thermal protection
EPS Specification - Rack load vs rack travel for
[A1114] 01452_13_00063 Yes
assistance performance
EPS specification –Rack load vs rack travel for city
[A1115] 01452_13_00063 Yes
park
Estimation of skin temperature for high severity
[A1118] 01452_11_00220 Yes
customers usage point
[A1119] 01452_13_00052 Safety dependability and durability requirements. Yes
[A1121] 02016_12_09367 DC_TI_70_Reprogrammation_des_UCEs Yes
[A1122] 01552_13_00739 ST FH CAN Yes

List of product functional and technical
[A1123] 01452_13_00128 Yes
characteristics (CTF)
EPS - Steering Assistance « Start up »,« Hold »
[A1125] 01452_12_00155 Yes
and « Shut down »
[A1126] 01452_09_00092 STT EPS Steering monitoring strategy Yes
[A1127] 00998_12_00471 DAE Additive CityPark Function TS Yes
[A1128] 01452_13_00053 Tableau de suivi de durabilité Yes
[A1129] 00998_12_01589 LKA Function TS Yes
[A1130] ILSI_CSLS06_0421 Cdc_EPS_Modelisation Yes
[A1131] BMPV_Specification_Safety_Req_Inputs- Yes

01452_13_00054
signals_template
[A1132] 01452_13_00055 EPS_DFMEA_Synthesis-Template Yes
[A1133] 01452_13_00067 DIA SDF EPS Yes
[A1134] 01552_13_01129 ST gestion multi-mode Yes
3.2.2 European guidelines

[A2010] 2000/53/CE Directive européenne traitement des véhicules hors d’usage. Yes
Directive européenne relative au marquage des pièces et des Yes

[A2040] 2003/138/CE
matériaux.

01452_13_00009 BMPV / 1V5 13/178
3.2.3 Functional and interface drawings
AA36859283 EPS 3D functional B-MPV DàG Yes
AA36859660 EPS 3D functional B-MPV DàD Yes
[A4010] AA36944699 EPS 3D functional 1V5 DàG Yes
AA36944700 EPS 3D functional 1V5 DàD Yes
01452_13_00069 EPS functional drawing Yes
[A4030] 01452_12_00143 Geometry for Grii Noise masselote Yes
[A4020] 01552_13_00738 ST Fonctions & Interface EPS Yes
3.2.4 French and international standards

Mark Document reference Document designation SPR access
Standard Practice for Modified Salt Spray (Fog)
[A2080] ASTM : G85-02e1 No
Testing
[A2081] NF EN 1561 Fonderie-Fonte à graphite lamellaire No
[A2082] NF EN 1563 Fonderie-Fonte à graphite sphéroïdale No

Aluminium et alliage d’aluminium –pièces moulées
[A2083] NF EN 1706 – composition chimique et caractéristiques No
mécaniques
Aluminium et alliage d’aluminium –système de
désignation applicable au lingot pour refusion en
[A2084] NF EN 1780-2 No
aluminium allié, aux alliages mère, et aux produits
moulés
[A2085] ISO 1629 Caoutchouc and Latex Nomenclature No
[A2090] NF EN ISO 1110 Plastiques - Polyamides - Conditionnement No

accéléré d'éprouvettes
3.2.5 PSA standards
SPR
Mark Document reference Document designation
access
A10 2260
[A3010] Marquage des produits de conception – Produits/Process Yes
Ind D (12/2011)
A12 5200
[A3020] Matériaux verts – Matériaux rebroyés – Définition Calcul Yes
Ind OR (07/2009)
A12 5500 Véhicules hors d’usage (VHU) - Données de composition
[A3021] Yes
Ind G (07/2011) masses matières et substances des pièces

01452_13_00009 BMPV / 1V5 14/178
SPR
access
A12 5510 Véhicules hors d’usage (VHU) – Aptitude à la dépollution du

[A3022] Yes
Ind OR (05/2005) véhicule
B15 3320 Revêtements à base de zinc lamellaire procédé en vrac ou à
[A3030] Yes
Ind B (04/2011) l'attache.
B15 4101 Revêtements de Zinc électrolytique et finitions associés procédé
[A3031] Yes
Ind E (04/2011) à l’attache.
B15 4102 Revêtements de zinc électrolytique et finitions associes procédé
[A3032] Yes
Ind C (06/2009) au tonneau (en vrac).
B18 0050
[A3040] Cotation véhicule trièdre de référence. Yes
Ind B (07/2009)
B20 0050 Nomenclature matériaux et procédés – Définition, Trames-type
[A3045] Yes
Ind OR (04/2011) & Processus
B20 0110
[A3046] Fourniture de produits prescriptions générales Yes
Ind H (12/2011)
B20 0150 Produits devant faire l’objet d’une spécification de produits
[A3047] Yes
Ind B (12/11/1997) approuvés – prescriptions générales
Recyclage et environnement – Réglementation VHU – Matériaux
B20 0200
[A3052] verts – Réglementation sur les substances chimiques (REACH, Yes
Ind D (12/2009)
…)
Substances / matières règlementées et restrictions d’usage dans
[A3059] B20 0250 Ind K Yes
le groupe PSA
B20 1220 Fourniture de pièces brutes de forge, extrusion, fonderie
[A3052bis] Yes
Ind D (02/2011) prescriptions générales
B20 1310
[A3053] Fournitures de pièces plastique – Prescription générales Yes
Ind F (01/2011)
B20 1315 Fournitures de pièces en plastiques, marquage d’identification
[A3054] Yes
Ind F (12/2007) des matières en vue du recyclage
B20 1415 Fournitures de pièces en caoutchoucs, marquage d’identification
[A3056] Yes
Ind G (12/2007) des matières en vue du recyclage
B20 4100 Cahier des charges générique pour équipements ou fonction
[A3057] Yes
Ind OR (01/2002) collé(e)s
B21 7100 Spécifications d’environnement des équipements électrique et
[A3060] Yes
Ind A (10/2005) électroniques – Caractéristiques générales
Spécifications Techniques Générales d’Environnement des
B21 7110
[A3061] Equipements Electriques et Electroniques – Caractéristiques Yes
Ind D (03/2012)
électriques
B21 7120
[A3062] Equipements Electriques et Electroniques - Caractéristiques Yes
Ind B (09/2005)
mécaniques
B21 7130
[A3063] Equipements Electriques et Electroniques -Caractéristiques Yes
Ind B (01/2012)
physico-chimique
B25 1140
[A3064] Faisceaux électriques / Validation des faisceaux Yes
Ind H

01452_13_00009 BMPV / 1V5 15/178
SPR
access
B51 0050
[A3090] Fontes de construction – Prescriptions générales Yes
Ind D (08/2009)
B51 1110
[A3091] Fontes de construction – Prescriptions métallurgiques Yes
Ind N
B53 3055
[A3092] Produits plats en acier ou en aluminium - essais Yes
Ind F (28/012009)
B54 1120 Aluminium et ses alliages – Alliages de fonderie pour pièces
[A3093] Yes
Ind E (01/2011) moulées
B62 0020 Matières thermoplastiques et thermodurcissables – Désignations
[A3065] Yes
Ind E (07/2008) conventionnelles
B62 0300 Matières thermoplastiques, thermodurcissables, élastomères
[A3066] Yes
Ind G (05/2011) thermoplastiques et caoutchoucs – Spécification
[A3067] B71 6000 Fluides de référence pour essais de compatibilité matériaux Yes
D13 5510
[A3068] Garniture et disques de frein - Mesure du potentiel libre Yes
Ind A (01/2010)
D14 1428 Produits antigravillonnage plastiques – caoutchouc résistance au
[A3069] Yes
Ind B (05/07/2002) grenaillage
D17 1058 Matériaux et revêtements – Essai de brouillard salin à 5% de
[A3075] Yes
Ind C (05/2008) NaCl et méthode de cotation.
D24 1312
[A3080] Revêtement de peinture - Résistance au gravillonnage. Yes
Ind E
D42 1235 Pièces en caoutchouc et en plastique – Comportement au choc
[A3081] Yes
Ind D (08/2008) (méthode par chute de masse)
CAOUTCHOUCS COMPACTS VULCANISES ELASTOMERES
D10 5010 ind A
[A3082] THERMOPLASTIQUES STANDARD D'ESSAIS MATERIAUX - NORMES Yes
(15/01/2013) EXTERNES
D47 1309 Matériaux et pièces d’équipement automobile – Vieillissement
[A3083] Yes
Ind F (11/2008) suivant cycle climatique donné
D45 1234 Pièce comportant des éléments en plastique – Comportement à
[A3085] Yes
Ind C (01/2008) la chaleur en étuve sèche non radiante
D47 1924 Plastiques et caoutchoucs – Contact occasionnel avec les
[A3087] Yes
Ind A (10/2007) fluides automobiles
D47 5478
[A3088] Matière plastiques – Tenue au chlorure de zinc Yes
Ind OR (10/2001)
3.2.6 PSA analysis procedures

Mark Document reference Document designation: Material analysis SPR access
[A4110] CPBM_CMPM06_0087 AN-PNO1 Expertise pièce neuve (plastique + métal) Yes
[A4120] CPBM_CMPM06_0088 AN-ECO1 Expertise après essai de corrosion Yes
[A4130] CPBM_CMPM06_0089 AN-EVO1 Expertise après essai de vibrations Yes
[A4140] CPBM_CMPM06_2167 AN-MPO1 Expertise matériaux plastiques Yes

01452_13_00009 BMPV / 1V5 16/178
Mark Document reference Document designation: Material analysis SPR access
Expertise détection / mesure fissuration sur
[A4150] CPBM_CMPM06_2169 AN-MPO2 Yes
boîtiers plastiques
[A4160] CPBM_CMPM06_2168 AN-MMO1 Expertise matériaux métalliques Yes
Expertise après actionnement d’un
[A4170] CPBM_CMPM06_0090 AN-EEO1 Yes
contacteur de commande (grain de contact)
[A4180] CPBM_CMPM06_2338 Expertise d’une zone de sertissage Yes

01452_13_00009 BMPV / 1V5 17/178
4 TERMINOLOGY
AAS Parking Help
AdD Failure Tree
AF Functional Analysis
FMECA Failure Modes, their Effects and Criticality Analysis
IGN Primary Ignition Supply
APR Preleminary Risks Analysis
ASIL Automotive Safety Integrity Level
BSI Current Distribution Box
BVA Automatic Gearbox
BVM Manual Gearbox
BVMP Driven Manual Gearbox
CAN Controller Area Network
CAN I/S CAN Inter System
CAV Steering Wheel Angle Sensor
EMC Electro-Magnetic Compatibility
CMM Multifunction ECU Engine
CPK City-Park (SCP6 et SCP9)
CSEO Electronic Components System Design
CTF Technical and Functional Characteristic
CSE Monitored Essential Characteristic
DA Power Steering (ibid EPS but other technology)
EPS Electric Power Steering
DC Design File
DJ Justification File
DMT Maintaining Voltage Device
EE Electricity Electronic
ER Feared Event
ESP Electronic Stability Program (trajectory correction system)
FMDS Reliability Availability Maintainability Safety
FNR Supplier
GMP Powertrain
IGN IGNition
IHM Man Machine Interface
LAS Chassis
LFM Latent Failure Metric
MPD Available Place Measurement
NA Not Applicable
PCP Parts Inspection Plan
PPM Parts Per Million
RETEX Experience Feedback
SCP Steering Comfort Program
SdF Reliability
SPFM Single Point Failure Metric
SSR Technical Specification of Safety and Regulatory
TS Technical Specification
STT STop and StarT
TBD Point To Be Define
ECU Electronic Control Unit
US Ultra-Sound
Vvh Vehicle Speed

01452_13_00009 BMPV / 1V5 18/178
5 REQUIREMENTS
All the requirements should be satisfied with a unique EPS configuration.
The requirements inside this paragraph are specified in the following conditions:
 Voltage across the terminals of the EPS  [8 ; 24] V
(Voltage at the interface between the EPS harness and the vehicle)
 EPS harness according to the functional drawings [A4010]. The supplier will describe its characteristics,
particularly the section and the resistance. This definition will be used to meet all the requirements.
 Temperature  [TminHF; TmaxHF].
 + IGN and GMP ON
 Valid vehicle speed
The forces to be considered for power assist at center (Fc) and at maximum efforts (Fm) on the rack are the
followings:
Reference scenario :
1V5-1 1V5-2 1V5-3 /B-MPV

Fc [daN] 380 400 430
Fm [daN] 650 700 750
Options :
Option 1V5-0 Option A Option B (73 mm) Option A+B (both)
Fc [daN] 350 429 428 429
Fm [daN] 600 790 776 802
The option A, B and A+B B-MPV are to be considered as risk and are not approved yet. The options have to be
considered as an opportunity to propose the lightest
Force to be considered for mechanical withstand at the rack end stop :
Reference scenarii
1V5-
1V5-1 1V5-2 B-MPV
3
Fm
1634 1725 1818 1830
[daN]
Options :
B-MPV A,
1V5-0 B-MPV A+B
B
Fm
1543 1830 1830
[daN]
The rack forces related to the travel are detailed in the reference file [A1111].

01452_13_00009 BMPV / 1V5 19/178
5.1 FUNCTIONAL REQUIREMENTS
5.1.1 Mechanism
KINEMATIC DATA
 BMPV/1V5_EPS_TS_SYSTEM_003: Mechanical link R
The product shall ensure the mechanical link between the input shaft and the ball joints on knuckles side.
Validation test: Design validation
 BMPV/1V5_EPS_TS_SYSTEM_004: Transmission of the efforts R
The product shall ensure the transmission of the mechanical efforts in both directions (driver=>knuckle and
knuckle=>driver) even in the case of accidental GMP shutdown.
 Driver direction => Knuckles: the driver action on the steering wheel inducing the rotation of the input shaft
shall conduct to the rotation of wheel knuckles (Sheet N°09).
 Knuckles direction => driver: the movements shall give feedback from the knuckles to the input shaft (Sheet
N°60).
Validation test: Test sheet N°09
Test sheet N°60
 BMPV/1V5_EPS_TS_SYSTEM_005: Meshing continuity R
The meshing shall be continuous. A couple of teeth shall be in contact before the previous one leaves it.
The characteristics of the rack teeth and the pinion shall be indicated on the drawing.

Reference: R15 4152 [R1130]
 BMPV/1V5_EPS_TS_SYSTEM_006: No free play R
No play on brand new part (F1 => Sheet N°33)

No play may appear until the stress F5 (N°33).
No play may appear after the tests N°20, N°21, N°102 and N°40.

Test sheet N°21
Test sheet N°33
Test sheet N°40
Test sheet N°102
 BMPV/1V5_EPS_TS_SYSTEM_007: Displacement way of the mechanism
The product shall be designed such as, for a mechanism placed in vehicle position (Standard PSA B18 0050
[A3040]), the clockwise rotation of the steering wheel leads the displacement of the rack on Y negative and vice
versa.

B18 0050 [A3040]
 BMPV/1V5_EPS_TS_SYSTEM_008: Pinion – rack ratio R
The input shaft / rack ratio should be defined as defined in the table below. This characteristic shall be indicated
on the drawing.
Hypothesis BMPV 1V5-1/3 1V5-2

Gear Ratio mm/rev Carry over A5 –A9 51 +/- 0,3 56 +/-0,3
PSA is open-minded for a variable gear ratio system. The supplier shall propose a solution with a round shape
(High gear ratio on center and low gear ratio at the end) which will not change the motor sizing done for a
constant

01452_13_00009 BMPV / 1V5 20/178
 BMPV/1V5_EPS_TS_SYSTEM_009: Half travel of the rack R
The half travel of the rack will be (see the table) mm with a tolerance of +/-1 mm (rack travel of xx mm with a
tolerance of +/-2 mm).
Project BMPV BMPV B and A+B 1V5
Half rack travel 72 73 76
Full travel 144 146 152
The supplier shall be able to suggest a solution to take into account the evolution of the rack travel during the
development (ex: adding of bushing …).
Validation test: Design validation with chain of dimensions.

 BMPV/1V5_EPS_TS_SYSTEM_010: Height of the mechanism

Z position of the point N can be able to vary :
Project BMPV 1V5 ref 1V5 explo 1 1V5 explo 2 1V5 explo 3 1V5 explo 4
Nominal value 2 2 4 6 10 12
(mm)
The supplier shall be able to suggest a solution to take into account this variation range. This height will remain
the same one on frame.
Reference: Functional drawings [A4010]
MECHANICAL RESISTANCE
 BMPV/1V5_EPS_TS_SYSTEM_011: Tightening torque of the wheel alignment R
The adjustment devices design shall withstand the torque defined by the supplier.
The tightening torque loss shall not exceed 20% of the initial torque applied after durability and fatigue test (N°20
N°21, N°102 and N°33).

Test sheet N°21
Test sheet N°33
Test sheet N°102

Functional drawings [A4010]
 BMPV/1V5_EPS_TS_SYSTEM_012: Tightening torque of the fastening on subframe R
The fastening elements (housing, stud) shall be designed according to the torques defined on the functional
drawings.
The tightening torque loss of the mechanism/subframe fastening after test (Sheet N°30) is allowed up to 25%.

Functional drawings [A4010]
 BMPV/1V5_EPS_TS_SYSTEM_013: Mechanical resistance R
The steering system shall not be damaged (crack, break of reduction gear tooth or pinion/rack tooth, seizing,
buckling of rack bar, deterioration of rack boots, …) after the tests below:

01452_13_00009 BMPV / 1V5 21/178
Test sheet N°21
Test sheet N°30
Test sheet N°40
Test sheet N°102
 BMPV/1V5_EPS_TS_SYSTEM_014: Tie rod Elasticity R
Each connecting tie rod with Outer Ball Joint fixed by its thread shall have a maximal displacement along the NM
axis of :
o 0,4 mm under +/-250 daN on brand new part during F1 and F3 R
o 0,8 mm under +/-250 daN after 25000 parking cycles during F5

o 1 mm under +/- 250 daN after 25000 parking cycles + 60 curb push away during F7 R
During the displacement measurement, the influence of the inner tie rod, and of the outer tie rod will be defined.
A fatigue test will also be performed on a part which has been submitted to an incidental shock for information
(steering system provided by PSA after incidental shock test on vehicle).
 BMPV/1V5_EPS_TS_SYSTEM_015: Resistance of the EPS harness connection with the mechanism

No damage during test and after test, such as uncoupling of the link Conductor/Contact. No cracks, separation,
detachment, tearing or cut is admitted.
 BMPV/1V5_EPS_TS_SYSTEM_016: Electric harness design

The electric harness shall be compliant with the standard requirements.

Reference: Standard B25 1140 [A3064]
FRICTIONS
 BMPV/1V5_EPS_TS_SYSTEM_017: Ball joint friction maximum effort
The ball joint tilting and rotational torque shall fulfill the following characteristics:
Test No.1 Test No.2
After 24h Test No.1 + 60 s
Maximum breakaway torque before tilting [N.m.] 12 9
Maximum tilting torque [N.m.] 3 3
Maximum breakaway torque before rotation [N.m.] 13 6
Maximum rotating torque [N.m.] 3 3
If the first measurement is higher than required, a second measurement will be done after 24 hours of storage at
ambient temperature.
 BMPV/1V5_EPS_TS_SYSTEM_018: Sliding effort and effort variation R
On brand new part (Test sheet N°07)

- Maximum xx N without rack boots (13 N more with rack boots) after relaxation. R The supplier shall propose a
target to achieve the value after wear-in

01452_13_00009 BMPV / 1V5 22/178
- Tolerance range around the nominal .value: +/-40N
- effort variation
|Fd max−Fd min| and |Fgmax −Fgmin|≤70 N
At the end of durability test (Test sheet N°20, N°21 and N°102)
- Maximum: lower than the value on brand new part
- Minimum: higher than 120N R
- effort variation
|Fd max−Fd min| et |Fgmax−Fg min|≤70 N
After wear-in (wear-in process detailed in test sheet 20):
- Maximum:
Project BMPV 1V5-1 1V5-2 1V5-3 (CUV)

Target 230 230 230 300
- Minimum: higher than 160N
- effort variation
After shock (Test sheet N°40)
- Maximum: lower than the value on brand new part
- Minimum: higher than 120N
- effort variation
Validation test: Test sheet No.07
Test sheet No.20
Test sheet No.21
Test sheet No.40
Test sheet N°102
 BMPV/1V5_EPS_TS_SYSTEM_019: Break-away effort

The following graphs shall be delivered:
- Plot 1: Vat_mass (t0) + (Tank_mass (t0) – Tank_mass (t))
- Plot 2: Displacement (t)
STEERING FLEXIBILITY
 BMPV/1V5_EPS_TS_SYSTEM_020: Steering flexibility
The supplier shall provide the graphs of the test sheet N°57.
5.1.2 Angle of the steering wheel

 BMPV/1V5_EPS_TS_SYSTEM_021: Steering wheel angle sensor Class 1
Reference: ST Inter-system [A4020]
 BMPV/1V5_EPS_TS_SYSTEM_022: Steering wheel angle sensor Class 3
Reference: ST Inter-system [A4020]

01452_13_00009 BMPV / 1V5 23/178
5.1.3 Assistance
 BMPV/1V5_EPS_TS_SYSTEM_023: Assistance – Tolerance on the assistance laws
This requirement shall be checked for the complete range of usual voltage [10,5V 16V].
 For each vehicle speed, the measured graphs shall be identical to the target graphs in the tolerances defined
below (Sheet N°01)
o  Cc  1 Nm admissible  0.35 Nm
o  1 Nm Cc 6.5 Nm admissible  0.53 Nm
o  Cc > 6.5 Nm admissible  0.7 Nm
 If there is a direct contact between the dash panel seal and the upper shaft, the assistance laws shall not be
disturbed by more than 0.1 Nm by the application of a radial effort.
 After durability (Sheets N°20, N°21 & N°102) or straight line shock (Sheet N°40) the tolerances on the
assistance laws shall comply with the values indicated above.
 After storage test (Sheet N°61) the tolerances on the assistance laws shall comply with the values indicated
above.

Test sheet N°20
Test sheet N°21
Test sheet N°40
Test sheet N°61
Test sheet N°102
 BMPV/1V5_EPS_TS_SYSTEM_024: Assistance – Asymmetry of assistance laws

This requirement shall be checked for the complete range of usual voltage [10,5V, 16V].
 A maximal right/left asymmetry of +/-0,3 Nm is accepted. For a given output effort, the value of the asymmetry
is defined by: (column torque left side –column torque right side)/2 (Sheet N°01)
 After durability test (Sheet N°20, N°21 & N°102), straight line shock (Sheet N°40) and storage (Sheet N°61),
the requirement shall be fulfilled.

Test sheet N°20
Test sheet N°21
Test sheet N°40
Test sheet N°61
Test sheet N°102
 BMPV/1V5_EPS_TS_SYSTEM_025: Assistance – Delay for assistance initialization
The product shall provide a nominal assistance in less than 500 ms (t1 – t0) after one of the assistance ignition
condition is fulfilled.

Reference: ST Diag and DTC EPS [A002]
01452_13_00094_BMPV_1V5_EPS_diagnostic_matrix [A006]
 BMPV/1V5_EPS_TS_SYSTEM_026: Assistance – Shutdown

The product shall not provide post-assistance after the fulfillment of shutdown conditions.
Reference: EPS - Steering Assistance « Start up »,« Hold » and « Shut down » [A1125]

01452_13_00009 BMPV / 1V5 24/178
 BMPV/1V5_EPS_TS_SYSTEM_027: Assistance – Assistance torque variation : Ripple
The steering wheel torque variation during parking maneuver shall not exceed ±0.1 Nm in the following
conditions :
- steering wheel torque on center : 3 Nm
- voltage [10,5V up to 16V]
- +/-540°
 BMPV/1V5_EPS_TS_SYSTEM_028: Assistance – smooth evolution of the assistance torque
This requirement shall be fulfilled for the complete range of usual voltage [10,5V; 16V] and vehicle speed [0Km/h
250Km/h].
The assistance torque evolution related to the vehicle speed variation shall be smooth and almost unapparent for
the driver. For each tested vehicle speed, this speed variation shall fulfill the following condition:
 Cc2> Cc1> 1 N.m with Vc2=VC1 + 1 km/h:
Cc1 - Cc2 < Min  0,2 N.m; 0,1* Cc1 ]
 BMPV/1V5_EPS_TS_SYSTEM_029: Assistance – Assistance level

The assistance level shall be adjusted according to:
 Vehicle speed:
 Range: [0 Km/h ; 250 km/h]. Over 250 km/h, use the maximal speed curve.
 Number of tuning points:
- 16 minimum if the pitch is variable and the range between two points could be ≤ 4 km/h (low
vehicle speeds need more accuracy).
- 24 minimum if the pitch is regular.
 Steering wheel torque measured by the torque sensor:
 Range: [-10 N.m; +10 N.m]. Over 10 N.m, use the maximal torque curve.
 Resolution  0,1 N.m
 Minimum number of tuning points: 32 (variable pitches). In particular the low torques will need more
accuracy.
 Neutral range: [-0,5 N.m ; +0,5 N.m]
 BMPV/1V5_EPS_TS_SYSTEM_0030: Assistance – Level of the assistance damping

The product shall include a damping function.
The level of damping shall be adjusted according to:
 Vehicle speed:
 Range: [0 Km/h; 250 Km/h]. Over 250 km/h, use the maximal speed curve.
 Number of tuning points: 16 minimum if the pitch is variable and the range between two points could be ≤
16 km/h (low vehicle speeds need more accuracy).
 Steering wheel speed:
 Range: [-1080°/s ; +1080°/s]
 Number of tuning points: 16 minimum if the pitch is variable and the range between two points could be ≤
16°/s (low steering wheel speeds need more accuracy).
 BMPV/1V5_EPS_TS_SYSTEM_031 : tuning material need

To ensure a good development process, the supplier shall provide the specific material need for communication
and tuning of its system.
 BMPV/1V5_EPS_TS_SYSTEM_186 : Assistance – Steering wheel dynamic limitation
01452_13_00009 BMPV / 1V5 25/178
The maximum steering wheel speed applied by the driver shall be tunable for a range of steering wheel speed
and a range of vehicle speed.
 Vehicle speed:
 Range: [0 Km/h; 250 Km/h]. Over 250 km/h, use the maximal speed curve.
 It should be possible to activate the function only for a range of vehicle speed
 Steering wheel speed:
 Range: [-1080°/s ; +1080°/s] Over the maximum steering wheel speed, use the maximal speed curve
 It should be possible to activate this function only for a range of steering wheel speed
Steering wheel speed [°/s]
Steering wheel speed – patch activated
Vv1
Vv4 Steering wheel speed – patch desactivated
Vv2
Vv3
Vehicle speed [Km/h]

0
Vh1 Vh2 Vh3 Vh4

With
Vh1 : Initial vehicle speed for patch activation. Patch activated at 0%
Vh2 : Vehicle speed 2
Vh3 : Vehicle speed 3
Vh4 : vehicle speed 4
Vv1 : Minimum steering wheel speed (based on the sizing of the assistance, without patch)
Vv2 : Steering wheel speed target maximum 1
Vv3 : steering wheel speed target maximum 2
Vv4 : Steering wheel speed target maximum 3
These 8 variables shall be tunable by calibration
 BMPV/1V5_EPS_TS_SYSTEM_032 : calibration file need

For each project 3 freezes have to be considered. The total amount of calibration file requested by PSA is 108 for
the complete project.
 BMPV/1V5_EPS_TS_SYSTEM_033 : Steering wheel return function
The supplier shall provide for all the diversity of system a function which allows the steering wheel to return on
Zero position whatever the braking system content of the car. This function shall be tuneable with the vehicle
speed.
 BMPV/1V5_EPS_TS_SYSTEM_187 : Control functions and control features availability
For the global module, the supplier shall be available to propose :

01452_13_00009 BMPV / 1V5 26/178
Function BMPV 1V5
Tuning capability Base function Base function
Damping function Base function Base function
Software end stops Base function Base function
Active return Base function Base function
Inertia compensation Base function Base function
Friction compensation Option Option
Leads and pull Option Option
compensation
Smooth road shake Option Option
compensation
For each function (ie in option) the supplier shall estimate the overall development cost needed to develop the
function.
 BMPV/1V5_EPS_TS_SYSTEM_034: Assistance – Functional description of the implemented functions
The supplier shall commit to provide a functional and technical description (Input/Output signals of different
blocks, the process performed on the signals, blocks description, motor control, tuning range or restrictions,
theoretical influence of the tuning parameters on the steering drivability, …) of implemented strategies (steering
wheel return function, inertia compensation, friction compensation …).The supplier shall indicate when the
function is fully available. Additional to that, the supplier shall provide a global explanation of the function.
To achieve the understanding of this module, the supplier shall provide to PSA a Simulink model of the EPS. This
model will allow PSA to understand the functional and dysfunctional behavior of the EPS.
Reference: Cdc_EPS_Modelisation [A1130]
 BMPV/1V5_EPS_TS_SYSTEM_035: Assistance – Stiffness torque sensor
The torque sensor torsion bar stiffness shall be 2.8 N.m/° minimum

01452_13_00009 BMPV / 1V5 27/178
5.2 PERFORMANCE REQUIREMENTS
Unless specific instruction the nominal supply voltage to be taken into account for the requirements
dealing with performance is 11,3V. The supplier shall thereby fulfill the requirements at this specified
supply voltage. The supplier shall also provide an answer for a 12,3V supply voltage (In STT mode, the
supply voltage stays at 10,5V). These values of supply voltage have to be considered at the terminal of EPS
harness (an impedance for this harness has therefore to be taken into account by the supplier)
5.2.1 List of the constraint functions

FC 01: Comply with standards.
FC 02: Signal the current EPS state of working to other systems in the vehicle
FC 03: Isolate the passenger compartment
FC 04: Respect and withstand the Components in mechanical interface
FC 05: Respect and withstand the environment.
FC 06: Respect and withstand the ambient Components
FC 07: Respect and withstand the test bench.
FC 08: Adapt to the energy sources
FC 09: Respect and withstand the driver
FC 10: Communicate with Components in EE interface.
FC 11: Resist to the constraints induced by the transport means.
FC 12: Respect and resist to the operator
FC 13: Respect and resist to the packaging
FC 14: Adapt to/ withstand the tooling equipment.
FC 15: Preserve the physical integrity of the passengers, of the driver and of the external people
FC 16: Integrate into the valorization streams
FC 17: Respect the ground clearance (if the lowest point belongs to the system)
FC 18: Adapt to and withstand the control means (including adjustment tool and diagnostic tool)
5.2.2 Compliance with standards

 BMPV/1V5_EPS_TS_SYSTEM_036: Standards
The product shall comply with standards and documents mentioned in §3.2 Applicable documents
Reference: §3 Indicated documents
5.2.3 Interface with other systems

The product shall respect the requirements of external interfaces of the 5.3. Moreover:
 BMPV/1V5_EPS_TS_SYSTEM_037: Interface – Operating state
Reference: TS functions and inter system interfaces [A4020]
 BMPV/1V5_EPS_TS_SYSTEM_038: Interface – Dash panel seal

The product shall have a compatible interface with the dash panel seal as defined on the functional drawings.

 BMPV/1V5_EPS_TS_SYSTEM_039: Interface – Fuel pipes

The product shall have a compatible interface as defined on the functional drawings.

01452_13_00009 BMPV / 1V5 28/178
 BMPV/1V5_EPS_TS_SYSTEM_040: Interface – Thermal shield
The product shall have a compatible interface as defined on the functional drawings.
 BMPV/1V5_EPS_TS_SYSTEM_041: Interface – Onboard power supply Voltage

The product shall be adapted to the onboard power supply voltages (usual, unusual and exceptional power
supply voltages).
For EPS requirements related to the power supply: see details in paragraphs 5.2.5 and 5.2.9.
Validation test: Test of the TS Hardware [A003]

Test sheet N°03
Reference: TS Hardware [A003]
ST diag and DTC DAE [A002]
5.2.4 Constraints with the external environment

 BMPV/1V5_EPS_TS_SYSTEM_042: External constraints – Emission of toxic or corrosive products
The product shall not use or emit toxic or corrosive products in the environment.
Reference: PSA Standard: B20 0250 [A3059]

PSA Standard : B20 0200 [A3052]
European Guideline 2000/53/CE [A2010]
 BMPV/1V5_EPS_TS_SYSTEM_043: External constraints – Inflammability and toxic emanations of the

product
Refer to the TS Hardware.
Reference: TS Hardware [A003]
 BMPV/1V5_EPS_TS_SYSTEM_044: External constraints – Resistance to the ozone

The product shall resist to the Ozone. The NBR rubber shall be ruled out on the exposed areas. The supplier
shall provide to PSA the list of the parts exposed to the outside area, their location on the EPS design and their
constituting material. This requirement will be validated with PSA.
Validation test: Test of the PSA Standard D10 5010 [A3082]

Reference: PSA Standard D10 5010 [A3082]
PSA Standard B62 0300 [A3066]
 BMPV/1V5_EPS_TS_SYSTEM_045: External constraints – Resistance to the chemical agents and

aggressive fluids
Following the the tests
 no change (cracks, bulging, partial dissolution, etc …) and no appearance modification shall be observed.
 the EPS shall be functional (performance, mechanical stability, etc …).
Remark: this test can be performed before the durability test (N°20 & N°21)
Validation test: Test B21 7130/CL25

Test sheet N°51
Reference: PSA Standard B21 7130 [A3063]

01452_13_00009 BMPV / 1V5 29/178
 BMPV/1V5_EPS_TS_SYSTEM_046: External constraints – Electromagnetic pollution R
The product shall not emit electromagnetic pollution.

The product shall withstand the electromagnetic disturbances and the ambient radiation.
Validation test: All the tests EQ/MC, EQ/MR and EQ/Irxx of the standard B21 7110 specified into TS HW [A003]
Hardware specification [A003]
 BMPV/1V5_EPS_TS_SYSTEM_047: External constraints – Resistances to electrostatic discharges

The product shall withstand electrostatic discharges.
Validation test: Resistance to the test EQ/IR03, and EQ/IR04

Reference: PSA Standard: B21 7110 [A3061]
Hardware specification [A003]
 BMPV/1V5_EPS_TS_SYSTEM_048: External constraints – No degradation of product during 5 years
storage duration
The product shall keep its integrity (Appearance, performances,…) during a minimum 5 years storage duration
without servicing. After a period 5 years, the product will be sent to the supplier for inspection.
Validation test: Test sheet N°61(Test B21 7130/CL01)

 BMPV/1V5_EPS_TS_SYSTEM_049: External constraints – Air tightness and water tightness
The product shall be airtight and watertight up to the following indexes:
 Index of water tightness and air tightness for passenger compartment area >= IP53
 Index of water tightness and air tightness for underhood area = IP68
 Index for high pressure water tightness = IPX9K
The risk areas (connectors) shall be protected before assembling to the vehicle.
If a problem of air tightness occurs following the test N°68, the test B21 7130/CL17 is required.
After tests N°69 and N°70, the product shall be disassembled to check that there is no trace of liquid penetration
inside the mechanism.
After test N°72, the product shall be disassembled to check that there is no trace of liquid penetration inside the
mechanism and the connector.
Validation tests: Test sheet N°52

Test sheet N°68 (Test B21 7130/CL13A)
Test sheet N°69 (Test B21 7130/CL13B
Test sheet N°70 (Test B21 7130/CL14)
Test sheet N°72 (Test B21 7130/CL16)
Test sheet N°75 (Test B21 7120/M3.1)
Test sheet B21 7130/CL17
Sequence A, B, C, H, I
 BMPV/1V5_EPS_TS_SYSTEM_050: External constraints – Water tightness and air tightness after

thermal shock
After test N°71:
 No degradation of performance shall be observed.
 There shall be no start of degradation which could affect the operation and the water tightness or air tightness
of the EPS. (observations according to the procedures of analysis CL28 and CL29 of the standard B21 7130)

Test sheet N°03
Test sheet N°71
Sequence D
01452_13_00009 BMPV / 1V5 30/178
 BMPV/1V5_EPS_TS_SYSTEM_051: External constraints – Resistance to gritting
The product shall resist to gritting projections type and to foreign matters on the road (ground clearance).
Validation test: Painted parts: PSA Standard D24 1312 [A3080]

For other coatings:
PSA Standard D17 1058 [A3075]
PSA standard D14 1428 [A3069]
 BMPV/1V5_EPS_TS_SYSTEM_052: External constraints – Resistance to humidity and corrosion
 Functional corrosion:
As it is a safety assembly, the EPS shall keep its functional integrity over a period of 15 years.
 Appearance corrosion:
Required protection:
 for the made-of aluminum parts: none
 for the made-of steel parts: table below:
Unthreaded
Coating Standard Threaded area
area
ZNI A3L
Bulk electrolytic zinc or
deposit for parts of sizes ZNI A3R ZNI A3R
B15 4102
< 150mm (submitted on
Central area beyond tie
=> degassing required PSA
rods and rack boots: area
validation)
located in low under the
hood (CPTB): Rack-treated electrolytic
Z15 FBR
zinc deposit for parts of B15 4101
ZNI A3R
sizes > 150mm
Lamellar zinc coating B15 3320 ZLV FGL ZLV FGO
Paint Prohibited
Rack-treated electrolytic Z20 FBR
Tie rods and rack boots B15 4101
zinc deposit ZNI A3L
area
Area located in or close to Lamellar zinc coating B15 3320 ZLV FGL ZLV FGO
the wheel arch submitted
to the gritting
Paint Prohibited
Important note:
The coatings choice according to the PSA requirements shall be presented by the supplier and will be submitted
to validation before the supplier choice.
The supplier shall indicate on his drawing the parts list and associated coatings which are in contact with the
external environment.


01452_13_00009 BMPV / 1V5 31/178
 BMPV/1V5_EPS_TS_SYSTEM_053: External constraints – Corrosion (CCA)
 The EPS shall be functional after the test (Sheet N°01)

 The EPS shall be airtight
Tests to be performed:
o Leakage rate measurement during an air overpressure test
o If the first control is NOK (leakage), the test N°70 has to be performed to find the leakage.
As a result we shall observe:

 No huge penetration of electrolyte inside the EPS at interfaces areas
 No corrosion or electro migration phenomenon on the electronic cards (or the inter-card links).
 No layer corrosion phenomenon on the housing at interfaces
 No « penetrating » or « cavernous » corrosion
 No penetrating crack of the plastic bases
 No deformation, cracks, breaking on metallic housings or rack boots
 No deterioration (perforation, crack, permanent deformation) of the components (rack boots, ball joints
protector for eg.)
To complete the optical analysis, the EPS shall be disassembled to perform a focus on all electric and electronic
parts (Routing or punch grid, electronic card, electronic components, …) - No incipient corrosion is allowed
On all the interfaces (Al / Al or Al / plastic), it is mandatory to perform micrographic sections to determine the
Aluminum degradation level. The following phenomena shall not be observed on the micrographic sections:
- Layer corrosion
- No crevice corrosion of the aluminum or penetrating corrosion
- Cavernous corrosion
- Spreading of the Al corrosion beyond 2mm on an EEE with relieved flange.
- Spreading of the Al corrosion under the plastic interfaces (flange, gore tex) / Al housing.
Micrographic sections are mandatory at interfaces after the SWAAT test.

An EPS rated level 3 is not compliant

01452_13_00009 BMPV / 1V5 32/178
 BMPV/1V5_EPS_TS_SYSTEM_055: External constraints – Corrosive thermal environment
At the end of each test, make the analysis of the parts according to [A4140].
 No crack, breaking, separation, detachment, tearing or fragmentation is allowed.
 Absence of deterioration (perforation, crack, permanent deformation) of the components (especially rack
boots, ball joints protector)
 The shall respect the requirement of watertightness and ai tightness of BMPV/1V5_EPS_TS_System_049
after this test.

Test sheet N°80
 BMPV/1V5_EPS_TS_SYSTEM_056: External constraints – Thermal air/air shocks
At the end of the test N°63:

 The EPS shall be completely functional. EPS shall be disassembled so as to perform complete analysis of
plastic parts (search for cracks or ageing). No internal and no external cracking shall be observed with a
binocular magnifier (x10) on plastic parts. Multi-material elements (over-molded, fixed, glued, screwed, etc.) and
welded elements which are sensible to the differential thermal widening effects have to be checked in particular.
 Visual inspection shall be done (test CL28/B21 7130): no visual degradation of internal and external faces is
allowed.
 No degradation of both internal and external visual shape of the electronic and electric components is allowed
(following visual inspection test CL28 / B21 7130)

Test B21 7130/CL28 [A3063]
Sequence E

01452_13_00009 BMPV / 1V5 33/178
5.2.5 Performances
Requirements below are related to minimum expected performances
The supplier shall indicate dispersion interval of the EPS performances (at 3).
PERFORMANCES RELATED TO THE STEERING WHEEL SPEED
 BMPV/1V5_EPS_TS_SYSTEM_057: Performance related to the steering wheel speed [Nominal voltage]

R
All measured points [steering wheel speed ; steering wheel torque] shall be lower than the following templates:
Maximum steering wheel torque [Nm]

Steering @ 11,3V for avoidance (2 & 2,5 rev/s)
wheel @12,3V for parking [-5°C ; Tmoy]
Fs [daN]  10 daN
speed As brand new part
[rev/s] After durability or straight
or before durability test
line shock, Assist ON
Assist ON
Torque target - 3 Nm -
1,54*Fc-0,64*Fm 2,5 9.0
0,9 * Fc 2 9.0 Value of Brand New part
0,9 * Fm 1,33 8.0 +5%
Fm Up to 1 8

Test sheet N°20
Test sheet N°21
Test sheet N°102
 BMPV/1V5_EPS_TS_SYSTEM_058: Performance related to the steering wheel speed [STT mode] R
All measured points [steering wheel speed ; steering wheel torque] shall be lower than the following templates:
Maximum steering wheel torque[Nm]

Steering STT @ 10,5V [ -5°C ; Tmoy]
wheel
Fs [daN]  10 daN
speed
[rev/s] As brand new part After durability test or
or before durability test straight line shock
Assist ON Assist ON
0,9 * Fc 2 9
Value of Brand New part
0,9 * Fm 1,33 8
+5%
Fm Up to 1 12

Test sheet N°20
Test sheet N°21
Test sheet N°102

01452_13_00009 BMPV/1V5 34/178
EVOLUTION OF THE ASSISTANCE TORQUE RELATED TO THE RACK TRAVEL
 BMPV/1V5_EPS_TS_SYSTEM_059: Assistance torque related to the rack travel [Nominal voltage]
The steering wheel torque shall not exceed the following limit:
Rack position Steering wheel torque (N.m)

(% of the NORMAL mode[-5 ; 90] °C
maximum travel) (12,3V)
SW speed Up to 360°/s
0 3
75 3
80 4.2
85 4.4
90 4.7
95 5.2
100 8
 BMPV/1V5_EPS_TS_SYSTEM_060: Assistance torque related to the rack travel [STT mode]

The steering wheel torque shall not exceed the following limit:
Rack position Steering wheel torque (N.m)

(% of the NORMAL mode[-5 ; 90] °C
maximum travel) (10,5V)
SW speed Up to 360°/s
0 3
50 4,1
68 6.0
75 7,2
85 9,0
99 12

01452_13_00009 BMPV / 1V5 35/178
PERFORMANCES ACCORDING TO TEMPERATURE AND SUPPLY VOLTAGE

 BMPV/1V5_EPS_TS_SYSTEM_061: Assistance performance = f(T°C, voltage) @ steering wheel speed <=
360 °/s R
 During Parking Maneuver: steering wheel speed <= 360°/s
Voltage [V]
[U_reset ; 8[ [8 ; 10,5[ 10,5 12,3 16 18 24
Total loss of assistance allowed
TminHF No irreversible degradation
CAN communication shall be ok
TminEF com CAN SPR 35 com CAN
Temperature [°C]
-20 com CAN SPR Nominal + 25% com CAN

-5 com CAN SPR Nominal com CAN
25 com CAN SPR STT Nominal com CAN
Tmoy com CAN SPR com CAN
Tmoy+5 com CAN SPR Nominal + 25% com CAN
TmaxE
F com CAN SPR Nominal + 50% com CAN
TmaxH
F Same target as TminHF
Maximal steering wheel torque (Nm) during parking maneuver
according to supply voltage and temperature
Table 1: requirements of maximum steering wheel torque on parking maneuver related to voltage and temperature
Com CAN: no assistance requested but CAN communication required.

SPR: Assistance required – Data to be defined with the supplier
U_reset: Reset voltage - to be defined with the supplier
The rack force to be taken into account is Fm (Cf. §5).

A linear interpolation shall be done to find the values between the specified points
No failure code shall be raised between TminHF and TmaxEF.

A failure code can be raised between TmaxEF and TmaxHF according to the diagnostic TS [A002]
The results will be graphically represented by positioning the measured points in the templates.
After test N°65, a detailed analysis of the electronic parts shall be done to check that there is no deterioration or
degradation of the components performance. A characterization of the current leakage at [25°C ; 11,3V] shall also
be done.

Test sheet N°61 (B21 7130/CL01)
Test B21 7130/CL02
Test sheet N°75 (B21 7120/M3.1)
Sequence A, B, C, D, E, F, G, H, I
ST Diag and DTC DAE [A002]

01452_13_00009 BMPV/1V5 36/178
 BMPV/1V5_EPS_TS_SYSTEM_062: Assistance performance = f(T°C, supply voltage) @ steering wheel
speed = 480 °/s R
 On fast Parking Maneuver: Steering wheel speed = 480°/s
Voltage [V]
[U_reset ; 8[ [8 ;10,5[ 10,5 12,3 16 18 24
Temperature [°C]

-5 com CAN SPR com CAN
Nominal
25 com CAN SPR Nominal : com CAN
STT
TmaxE
TmaxH
Table 2: requirements of maximum steering wheel torque on fast Parking Maneuver according to supply voltage
and temperature
Com CAN: no performance level requested but CAN communication required.

SPR: Required assistance – Data to be defined with the supplier
U_reset: Reset Voltage - to be defined with the supplier
The rack force to be taken into account is 0,9*Fm (Cf. §5).
 No failure code shall be raised between TminHF and TmaxEF.

 A failure code can be raised between TmaxEF and TmaxHF according to the diagnostic TS [A002].
After test N°65, a detailed analysis of the electronics shall be done to check that there is no deterioration or
be done.

Test B21 7130/CL02
Test sheet N°75 (B21 7120/M3.1)

01452_13_00009 BMPV / 1V5 37/178
 BMPV/1V5_EPS_TS_SYSTEM_063: Assistance performance = f(T°C, voltage supply) @ steering wheel
speed = 720 °/s R
 During an avoidance maneuver: steering wheel speed = 720°/s
Voltage [V]
[U_reset ; 8[ [8 ; 10,5[ 10,5 12,3 16 18 24
Temperature [°C]

25 com CAN SPR STT Nominal : com CAN
TmaxE
TmaxH
Table 2: requirements of maximum steering wheel torque during an avoidance maneuver according to voltage
supply and temperature

SPR: Required assistance – Data to be filled out by the supplier
U_reset: Reset Voltage - to be defined by the supplier
The rack force to be taken into account is 0,9*FC (Cf. §5).


be done.

Test B21 7130/CL02
Test sheet N°75 (B21 7120/M3.1)

01452_13_00009 BMPV / 1V5 38/178
 BMPV/1V5_EPS_TS_SYSTEM_64: Assistance performance = f(T°C, voltage supply) @ steering wheel

speed = 900 °/s R
 During an avoidance maneuver: steering wheel speed = 900°/s

Voltage [V]
[U_reset ; 8[ [8 ; 10,5[ 10,5 12,3 16 18 24
Temperature [°C]

25 com CAN SPR STT Nominal : com CAN
TmaxE
TmaxH
Table 3: requirements of maximum steering wheel torque during an avoidance maneuver according to voltage
supply and temperature

SPR: Required assistance – Data to be filled out by the supplier
U_reset: Reset Voltage - to be defined by the supplier
The rack force to be taken into account is 0,9/7*(12Fc-5Fm) (Cf. §5).


be done.

Test B21 7130/CL02
Test sheet N°75 (B21 7120/M3.1)

ST Diag et DTC DAE [A002]

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 BMPV/1V5_EPS_TS_SYSTEM_065: Thermal cycle durability
At the end of each cold cycle, the EPS shall fulfill the requirements (BMPV/1V5_EPS_TS_SYSTEM_61 to
BMPV/1V5_EPS_TS_SYSTEM_64) the functional points specified at TminEF.
At the end of each hot cycle, the mechanism shall fulfill the requirements BMPV/1V5_EPS_TS_SYSTEM_61 to
BMPV/1V5_EPS_TS_SYSTEM_64) for the functional points specified at TmaxEF.
Validation test: Test sheet N°64 (B21 7130/CL08)

Sequence D, H, I
STEERING WHEEL TORQUE DURING AN AVOIDANCE MANEUVER

 BMPV/1V5_EPS_TS_SYSTEM_066: Steering wheel torque during avoidance (dynamic scenarios)
The steering wheel torque measured during avoidance test (N°91) shall be lower than the specified values below.
Measurement conditions :
 ambient temperature = Tmoy
 input voltage = 11,3V
Steering wheel speed

Steering wheel torque
[Nm]
[rps]
2 <6
2.5 <6
The following graphs shall be plotted with respect to time:

- Measured and theoretical effort
- Measured steering wheel torque
- Measured and theoretical steering wheel angle
The difference between setpoint values and the measured ones shall be lower than 2%.
PERFORMANCE OF THE THERMAL SIZING

In case of intensive use, the product shall ensure the following minimal performances:
 BMPV/1V5_EPS_TS_SYSTEM_067: Thermal performance – Rack End hold
 Rack End hold test (first part of test sheet N°06)
o The motor and controller skin temperatures shall not exceed Tmax_EF
o During the parking maneuver, the requirements BMPV/1V5_EPS_TS_SYSTEM_61 to
BMPV/1V5_EPS_TS_SYSTEM_64) shall be fulfilled.
o The motor and controller skin temperatures shall not exceed Tmax_HF during a period of 60 minutes
after the stop of the test.
It is possible to replace this component test by an in-car measurement. In this case, the test conditions and the
results have to be shared and submitted to PSA for approval.

01452_13_00009 BMPV / 1V5 40/178
 BMPV/1V5_EPS_TS_SYSTEM_068: Thermal performance – Effort constraint
 Effort constraint test in test sheet N°06 (2nd part)
o From 0 to 5 elementary maneuvers minimum: no degradation of nominal performances
BMPV/1V5_EPS_TS_SYSTEM_61 to BMPV/1V5_EPS_TS_SYSTEM_64)
o From 6 to 10 elementary maneuvers: a degradation of 20% of nominal performances is allowed
BMPV/1V5_EPS_TS_SYSTEM_61 to BMPV/1V5_EPS_TS_SYSTEM_64)

It is possible to replace this component test by an in-car measurement. In this case, the test conditions and the
results have to be shared and submitted to PSA for approval.
 BMPV/1V5_EPS_TS_SYSTEM_069: Thermal performance – Thermal peak PTR2

 Thermal peak PTR2 in test sheet N°06 (3rd part)
o During the « thermal peak PTR2 » cycle, the EPS shall perform the 2 requested parking maneuvers in a
row at nominal performances according to (BMPV/1V5_EPS_TS_SYSTEM_61 to
BMPV/1V5_EPS_TS_SYSTEM_64).
o No permanent degradation is allowed (self-protection of the EPS in case of intensive use).
 BMPV/1V5_EPS_TS_SYSTEM_070: Thermal performance – Self-heating

 The maximal component temperature shall never be reached (thermal self-protection)
 Whatever the chosen thermal profile (to be defined in the test plan), the thermal self-protection of the EPS has
to be designed so as to stay below each components maximal temperature.
 The maximal temperature of the PCB shall not exceed Tg = 1,15xTmaxEF (Tg=glass temperature of the PCB)
 BMPV/1V5_EPS_TS_SYSTEM_071: Thermal performance – Operating limit at temperature
The test shall be continued until a failure occurs.

The failure shall be analyzed (disassembling, material analysis, EE tests …).
Validation test: Test sheet N°67 (B21 7130/CL11)

01452_13_00009 BMPV / 1V5 41/178
High speed parking maneuver
 BMPV/1V5_EPS_TS_SYSTEM_072: Parking stirring [Nominal voltage]
Power supply voltage: 12,3 V

Operating condition : [-5°C ; Tmoy]
Measurements of steering wheel torque peaks shall be lower than the values inside the following template (each
peak of torque is associated with a peak of steering wheel speed):
Steering wheel Steering wheel

speed [°/s] torque [Nm]
0 5
500 5
600 7
700 12
800 20
900 30
The time lag between the steering wheel angle peaks and the steering wheel torque peaks shall be plotted.
The difference between the effort or steering wheel angle setpoint and the measured one shall be lower than 2%.
 BMPV/1V5_EPS_TS_SYSTEM_073: Parking stirring [STT mode]
Power supply voltage: 10,5 V

Operating condition : [-5°C ; Tmoy]
Measurements of steering wheel torque peaks shall be lower than the values inside the following template (each
peak of torque is associated with a peak of steering wheel speed):
Steering wheel Steering wheel

speed [°/s] torque [Nm]
0 5
450 5
500 7
600 12
700 20
720 30
The time lag between the steering wheel angle peaks and the steering wheel torque peaks shall be plotted.
The difference between the effort or steering wheel angle setpoint and the measured one shall be lower than 2%.
CENTERING AND HYSTERESIS

 BMPV/1V5_EPS_TS_SYSTEM_074: Hysteresis characterization
The assistance law hysteresis of the product shall be characterized.
 BMPV/1V5_EPS_TS_SYSTEM_075: Centering – Hysteresis

This requirement is applied on the power supply voltage range [10,5V 16V].
The product shall have a centering that fulfill the following requirements:
 Torque hysteresis:
-- Nominal: 1.9 N.m
-- Adjustment range: [1 ; 3.2] N.m
01452_13_00009 BMPV / 1V5 42/178
 Angle hysteresis:
-- Nominal: 3.4 °
-- Adjustment range: [2.5 ; 6.5] °

Test sheet N°56
LOW SPEED CORNERING

 BMPV/1V5_EPS_TS_SYSTEM_076: low speed cornering
The final steering angle shall fulfill the following condition: (1- (3 / V2 ))*100 >90%
Steering wheel angle shall not exceed center position.
5.2.6 Road feedback

FORCE STRESS
 BMPV/1V5_EPS_TS_SYSTEM_077: Road feedback – Force stress
The measured frequency response functions (margin and Phase => H = Steering_wheel_torque / Rack_force) shall
be included into the following templates.
 On straight line:
Fonction de transfert couple volant / effort crémaillère

0 +/- 50 daN Volant bloqué
4,4.10^-3
4.10^-3
Gain (Nm/N)
3,6.10^-3
Pente :
0,35.10^-3 (Nm/N)/Hz
1 10 20
Fréquence (Hz)
Fonction de transfert couple volant / effort Frequency response function steering wheel
crémaillère torque / rack effort
Volant bloqué Locked steering wheel
Gain Margin
Fréquence Frequency
Phase (degré) Phase (degree)
Pente Slope

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0
Phase (degré)
-30
1 10 20
Fréquence (Hz)
Fonction de transfert couple volant / effort Response function steering wheel torque / rack
crémaillère effort
Volant bloqué Blocked steering wheel
Gain Gain
Fréquence Frequency
Phase (degré) Phase (degree)
Pente Slope
 On lock:
7,7.10^-4
7.10^-4
Gain (Nm/N)
6,3.10^-4
Pente :
0,3.10^-4 (Nm/N)/Hz
1 10 20
Fréquence (Hz)
Fonction de transfert couple volant / effort crémaillère Frequency response function steering wheel torque /
Volant bloqué rack effort
Gain Locked steering wheel
Fréquence Margin
Pente Frequency
Slope

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0
Phase (degré)
-30
1 10 20
Fréquence (Hz)
Fonction de transfert couple volant / effort crémaillère Frequency response function steering wheel torque /
Volant bloqué rack effort
Fréquence Locked steering wheel
Phase (degré) Frequency
Pente Phase (degree)
Slope
Considering the current knowledge on the information feedback, PSA can change the target response functions
below during the development.
DISPLACEMENT STRESS
 BMPV/1V5_EPS_TS_SYSTEM_078: Information feedback – Displacement stress
The measured frequency response functions (Margin and Phase H = Steering_wheel_torque / Rack_effort) shall
be provided.

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5.2.7 Inertia feeling
 BMPV/1V5_EPS_TS_SYSTEM_079: Inertia feeling
The frequency response function H = Column torque / Steering wheel angle shall have the following
characteristics:
 Margin: |G| ≤ 10% with G maximum difference between margin on frequency range [0 to 2 Hz] and static
margin Gstat
 Phase: Maximum delay between the steering wheel torque and steering wheel angle on the frequency range [0
to 5 Hz]: ≤ 0,05 s
5.2.8 Additional requirements of STTa function
 BMPV/1V5_EPS_TS_SYSTEM_080: STT – Electric power STOP mode

The supplier shall propose a strategy which allows reducing the electric power taken from vehicle power supply
during STOP mode maneuvers (STOP mode specified in the TS Diag and DTC EPS).
Software parameters of this strategy shall be adjustable during the development (limitation level for eg.).
Reference: TS Diag and DTC EPS [A002]

 BMPV/1V5_EPS_TS_SYSTEM_081: STT Transition – Approval

The transition between "Normal" and "STOP" modes shall be done by limiting the impact on the steering
drivability (see TS Diag and DTC EPS). This strategy shall be tunable during the development (transition
gradients).
Reference: TS Diag and DTC EPS [A002]
 BMPV/1V5_EPS_TS_SYSTEM_082: STT Transition – Avoidance maneuvers

During the transition phases "Normal" mode/ "STOP" mode, the product shall be able to take into account the
important variations of assistance setpoint (avoidance maneuvers).
 BMPV/1V5_EPS_TS_SYSTEM_083: STT Transition – Overheating

When the protection strategies against the electronic components overheating are activated: [the product shall

01452_13_00009 BMPV / 1V5 46/178
not allow the transfer to "STOP" mode] AND [the product shall request the transfer to "Normal" mode].
 BMPV/1V5_EPS_TS_SYSTEM_084: STT Transition – Comfort strategies

The "comfort" strategies (active steering wheel return, rack end, etc...) shall not lower the steering drivability on
"STOP" mode (specific development, potential deactivation...)
5.2.9 CityPark function requirements

POWER ASSISTANCE NEED
 BMPV/1V5_EPS_TS_SYSTEM_085: CityPark Function – Power need

The system shall be able to meet the power needs specified below. The measurement and the requirements are
specified in the paragraph 4.2.3 with the difference that the steering wheel maneuvers are replaced by the
sending of a steering wheel angle setpoint to the CAN. Remind that the requested performances below
correspond to the minimal definition of the proposed steering systems. The supplier should specify the
performance dispersions at 3.
Steering wheel torque Steering wheel

Steering wheel
Rack travel acceleration [°/s²]
speed [°/s]
[Nm]
67,5% 450 0 1000 max.
76% 350 0 1000 max.
85% 200 0 1000 max.
90% 0 0 1000 max.
The product shall meet these performances:

 for all voltages between 11,3V and 16V
 for all temperatures between -20 °C and Tmoy+5
Beyond this functional range:

 Performance not requested
 CAN communication available.
 No irreversible degradation

Reference: DAE Additive CityPark Function TS [A1127]
CITYPARK ANGLE CONTROL PERFORMANCE
 BMPV/1V5_EPS_TS_SYSTEM_086: CityPark Function – Angle control

For the ambient temperatures underhood around the EPS of -20°C, Tmoy and Tmoy+5,
For voltages across EPS of 11,3V, 13,5V and 16V,
• The angle measurement shall follow the City Park steering wheel angle set point with a total time lag of
maximum 100ms including the pure delay and the drag error. This presents a dynamic error of maximum
45° for a steering wheel speed of 450°/s. The static error shall be lower than 5°.
The total time lag shall be constant and shall not fluctuate during the tests.

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Asservissement CityPark en Manoeuvre parking CityPark
600
Consigne d angle CITYPARK
Mesure d angle volant
500
Erreur statique ≤5°
Consigne et mesure d angle volant CityPark
400
300
200
100
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Temps [s]
Asservissement CityPark en Manoeuvre parking CityPark CityPark parking maneuvers control

Consigne et mesure d’angle volant CityPark CityPark steering wheel angle setpoint and measurement
Consigne d’angle CityPark CityPark angle setpoint
Mesure d’angle volant Steering angle measurement
Erreur statique Static error
Retard Delay
Temps Time
The supply voltage shall not impact the results.

Validation tests: Test sheet STRESSN°100
Reference: EPS Additive CityPark Function TS [A1127]
THERMAL SIZING
 BMPV/1V5_EPS_TS_SYSTEM_087: CityPark Function – Thermal sizing
For ambient temperatures around EPS of -20°C, Tmoy and Tmoy+5,

For voltages across EPS of 11,3V, 13,5V and 16V,
1) The system shall be able to achieve 4 CityPark cycles (without break) without Derating.
2) The system shall be able to achieve 4 CityPark cycles more (cycle above) after a 3 minutes break.
3) The control performances during the whole test shall comply with the requirement
BMPV/1V5_EPS_TS_SYSTEM_086.
Number of City Park Voltage (V)

parking maneuvers for
each City Park cycle 11,3 13.5 16
-20 ≥5 ≥5 ≥5
Temperature
Tmoy ≥5 ≥5 ≥5
(°C)
Tmoy+5 ≥5 ≥5 ≥5
Reference: DAE Additive CityPark Function TS [A1127]

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DURABILITY
 BMPV/1V5_EPS_TS_SYSTEM_088: CityPark Function – Durability R
The system shall meet the same requirements as for the Test sheet Loads (§Error: Reference source not found).
Before and after durability, the system shall meet the requirements,BMPV/1V5_EPS_TS_SYSTEM_085
BMPV/1V5_EPS_TS_SYSTEM_086 and BMPV/1V5_EPS_TS_SYSTEM_087
Validation tests: Test sheet CityPark cycle definition:

Reference: EPS Additive CityPark Function TS [A1127]
5.2.10 Lane Keeping Assist
 BMPV/1V5_EPS_TS_SYSTEM_089 : Lane Keeping Assist
Reference : ST LKA [A1129]
5.2.11 Multi mode assistance
 BMPV/1V5_EPS_TS_SYSTEM_090 : Multi-mode Assistance

The system shall be able to switch while driving on different assist curve law by the reception of a software
request. 3 modes shall be available. : Comfort, normal, sport.
- With LKA activated it is possible to switch to another mode
- In case of switching error (failures), the EPS stays in the current mode
- At the start up of the car, the EPS is in normal mode
The supplier shall propose a function which allows the EPS to switch to different mode.
At least, the supplier shall propose to tune the following parameters :

- Base map (all situation life)
- Damping parameter
- Stability parameter
- Torque filter parameter
Reference : ST multi-mode management [A1134]

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5.2.12 Mechanical resistance

 BMPV/1V5_EPS_TS_SYSTEM_091: Mechanical resistance – Vibration R
 Search and study of natural frequencies (or critical frequencies)

During and after the test there shall be no deterioration of mechanical characteristics, water tightness, air
tightness, or electric characteristics. If it is necessary to check the EPS operation during the test, the EPS can be
powered on.
 Random vibrations
After the test, there shall be no deterioration of mechanical characteristics, water tightness, air tightness, or electric
characteristics. The EPS has to be powered on but shall be not functional during the whole test (so as to
reproduce its self heating).
The supplier shall check regularly during the test (by shutting down the vibration) that the EPS is still functional.
The functional characteristic is therefore checked by a static test during and after the vibration test.

Test sheet N°70
Sequence A
 BMPV/1V5_EPS_TS_SYSTEM_092: Mechanical resistance – Maximal, incidental and accidental forces

R
The product has to fulfill the following requirements:
 The product has to resist without any deformation to the maximal forces specified in paragraph 6.1.2 .
 A tie rod deformation is allowed in the case of « incidental » impacts. The product has to stay functional.
 An important tie rod deformation (see 6.1) is required in the case of « accidental » impacts. The tie rod has to
be the component which is deformed (the fuse) in case of accidental impact.
See the test procedure detail below:

Test procedure for the tie rods behavior requirement:
1) Tie rod resistance verification at maximal effort with the Test sheet N°33
2) Tie rod behavior evaluation. The following results are deduced:
 Energy level at breakage,
 Buckling energy E (in J). This energy shall be upper than the energy specified below:
Buckling energy specified = 0,22*MTAC+6
Reference
1V5-1 1V5-2 1V5-3 B-MPV
Energy 195 206 217 217
Option
1V5-0
Energy 185
A large tie rod deformation shall appear at an energy level lower than the one leading to a failure of the
mechanism. The tie rod shall be the fuse.
3) The tests sheets N°40 and N°41 have to be completed. No failure is allowed below the energy level E. The
supplier shall ensure particularly that no material is broken away (which may move to the rack teeth and cause
Feared Events (ER) of gravity 3 or 4).
4) Tie rod behavior during impacts:
4.a) digital approach (Cf. 6.1)
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4.b) experimental approach (on PSA vehicle)
5) After an « incidental » impact, the EPS has to be able to perform a complete durability test without failure: test
sheet N°20, N°21 & N°102.

Test sheet N°21
Test sheet N°33
Test sheet N°40
Test sheet N°41
Test sheet N°102
Reference: Appendix § 6.1
 BMPV/1V5_EPS_TS_SYSTEM_093: Mechanical resistance – Resistance to driver R
The product has to resist to the aggressions coming from the driver (torque efforts, stresses).
 There shall be no degradation of functional characteristics (test sheets N°01 and N°07) when the product is
stressed with an input shaft torque of 100 N.m.
 At a stress of 150 N.m, the maximal remaining deformation has to be 3 degrees between input shaft and pinion.
The durability characteristics have to stay unchanged.
 The maximal evolution of the sliding force is 15N.
 At 200 N.m, the breakage is allowed but only if it comes with a large prior deformation, visible to the naked eye.
The fuse shall not be the torsion bar.
5.2.13 Assembly
 BMPV/1V5_EPS_TS_SYSTEM_094: Assembly – Degradation
The product shall not be damaged during the assembly.
Validation test: Test sheet N°75 (B21 7120/M3.1)
 BMPV/1V5_EPS_TS_SYSTEM_095: Assembly – Tooling equipment

It shall be possible to assemble the product in the vehicle by means of the standard tooling or specific existing
tooling. It shall also be possible to assemble the product in the vehicle without the use of any other products (glue,
lubricant, harmful product...)
 BMPV/1V5_EPS_TS_SYSTEM_096: Assembly – Tightening efforts

The system has to withstand the tightening and loosening efforts specified on the functional drawings.
 BMPV/1V5_EPS_TS_SYSTEM_097: Assembly – assembly efforts

The installation of the steering ball joint on the knuckles, until the nut is pined, shall be possible to be performed
manually by an operator without any adding tools. For this, the required effort to approach the steering ball joint to
the knuckle shall not exceed 95N for X<12mm.

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5.2.14 Quality
 BMPV/1V5_EPS_TS_SYSTEM_098: Quality – Inspection report
Respect the PSA formalism regarding inspection reports.
Reference: DA_MQF05_0002_EX_En_V006 [A1021]
5.2.15 Acoustic level

PRODUCT ACOUSTIC RADIATION
 BMPV/1V5_EPS_TS_SYSTEM_099: Acoustic – Radiation
In operating conditions of the thermal engine at idle and accelerated speeds, the steering system shall not be
audible by the passengers of the vehicle and not also by people from the outside.
The 1/3 octave in dB(A) spectrum of the system acoustic radiation on close field shall meet the template below:
Bruit rayonné en dB(A) Radiated noise in dB(A)

Fréquence (en Hz) Frequency (in Hz)
The global noise level of the system shall be lower than 39 dB(A).
For information, it is required to superimpose the narrow band spectrum with the 1/3 octave spectrum.
The validity of the results shall be verified in a voltage range of 10.5 to 14.5V across the product terminals.

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BLOCKING EFFORTS
 BMPV/1V5_EPS_TS_SYSTEM_100: Acoustic – Blocking efforts
The requirements have to be fulfilled on the whole system (sum of the efforts from sensors 1 and 2) for the axis X,
Y and Z are:
Fx=Fx1 + Fx2 Fy=Fy1 + Fy2 Fz=Fz1 + Fz2
On the whole use range (speed, torque), for the straight line situation and maneuver (without rack end shock), the
system shall fulfill for each axis X, Y and Z, the template below:
1
Efforts (en N)
0.1
0.1
0.01
0.01
0.0025
0.001
100 1000 4000 10000
Fréquence (en Hz)
The validity of the results shall be verified in a voltage range of 10,5 to 14,5V across the product terminals.
EPS SYSTEM BLOCKING EFFORTS WITH A « BACK-LASH » EXCITATION TYPE AND

RACK END EPS SYSTEM BLOCKING EFFORTS
 BMPV/1V5_EPS_TS_SYSTEM_101: Acoustic – Blocking efforts / « back-lash » excitation type
The requirements have to be fulfilled on the whole system in reversal steering situation and at end stop (sum of
the efforts from sensors 1 and 2) for the axis X, Y and Z are:
Fx=Fx1 + Fx2 Fy=Fy1 + Fy2 Fz=Fz1 + Fz2
1
0,5
Efforts (en N)
0,1
0,03
0,01
0,0075
0,001
100 1000 4000 10000
Fréquence (en Hz)

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GRII NOISE
 BMPV/1V5_EPS_TS_SYSTEM_102: Acoustic – Grii Noise type
This requirement has to be fulfilled by the supplier on the whole system. The system has to respect the followed
pattern for Y vehicle axis (peak value). The data are recorded on the upper shaft.
10Hz 250Hz 4000Hz
0,6 0,6 0,01
 BMPV/1V5_EPS_TS_SYSTEM_188: Acoustic – subjective in-car evaluation

During the durability test N°21, PSA and the supplier will have to evaluate the behavior of the system on acoustic
stand point. Theses evaluation will be done at 0, 20, 60 and 100% of the durability test.
The objective of PSA for these evaluation are

0 20 60 100
target 8,25 7,5 7 6,5

5.2.16 Diagnostics and calibration
 BMPV/1V5_EPS_TS_SYSTEM_103: Diagnostics/Calibration – Parameters downloading
It shall be possible at the plant to download parameters sets via the CAN network
It shall be possible at the plant to activate or desactivate some EPS function (STTx, configuration ESC/ABS ….)
via variant coding.
Reference: Software TS [A004]

ST diag and DTC EPS [A002]
Safety dependability and durability requirements [A1119]
 BMPV/1V5_EPS_TS_SYSTEM_104: Diagnostics/Calibration – Development tools

The supplier shall provide the needed tools for the EPS development (estimated quantity of 8).
For each tunable parameter via this tool, the tuning range has to be specified. The development compatibility
performed by PSA with the EPS is the Supplier’s responsibility (the supplier shall particularly ensure the driving
stability, the noise or vibrations absence...).
 BMPV/1V5_EPS_TS_SYSTEM_105: Diagnostics/Calibration – Recoverable elements on the CAN

network
The product shall be able to provide on the CAN network the required data requested by the diagnostic tool. See
in doc [A002] the detailed requirements.

 BMPV/1V5_EPS_TS_SYSTEM_106: Diagnostics/Calibration – Battery non-discharge
The product shall not discharge the vehicle battery during the parameter set, the diagnostic or calibration session.
The maximal consumption values during these sessions are specified in doc [A003]
Reference: DAE Hardware TS [A003]
 BMPV/1V5_EPS_TS_SYSTEM_107: Diagnostics/Calibration – Co-design/ diagnostic ability /Diagnostic

Synthesis Table
The supplier shall commit to cooperate with PSA in the procedure of co-design/ diagnostic ability. The supplier
shall especially fill out the diagnostics summary table file (Diagnostic Synthesis Table).
Reference: ELECTRIC POWER STEERING DIAGNOSTIC ABILITY REQUIREMENTS [A1100]

Guide of diagnostic ability summary table use [A1101]
Diagnostics Summary Table [A1102]
CPPR [A1030]
5.2.17 Incident/Accident
 BMPV/1V5_EPS_TS_SYSTEM_108: Incident / Accident
In case of incident / accident, the product shall not wound people in the car
The meshing of the product shall be provided to PSA according to ILSI_AFDH06_0763 TS [A005].
Validation test: PSA digital validation
Reference: ILSI_AFDH06_0763 [A005]

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5.2.18 Electric consumption
 BMPV/1V5_EPS_TS_SYSTEM_109: Electric consumption - Measurements
For an ambient temperature of Tmoy, the following measurements shall be provided:
 The following time graphs:
 Current
 Voltage across the EPS
 Steering wheel torque
 Steering wheel speed
 The average consumed current:
 The average of the consumed current in the area of +/-30mm around the middle point if the
steering wheel speed is not zero.
 The current consumption value if the steering wheel speed is zero
Static Average consumption of ±30 mm of the travel

Rack end
consumption (A) around the 0 (A)
effort (daN)
Steering wheel speed 0 rps 0,2 rps 0,5 rps 1 rps
Steering 3 Nm SPR SPR SPR SPR Fm
wheel 4 Nm SPR SPR SPR SPR Fm
torque SPR SPR SPR SPR
5 Nm Fm
SPR: Data to be filled out by the supplier
5.2.19 Ground clearance

 BMPV/1V5_EPS_TS_SYSTEM_110: Ground clearance
The product has to meet the ground clearance requirements specified in the functional drawings [A4010].

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5.3 EXTERNAL INTERFACE REQUIREMENTS
 BMPV/1V5_EPS_TS_SYSTEM_111: External interfaces – Vehicle integration

The product has to fit in the vehicle, and comply with the characteristics quoted on the functional drawings.
 BMPV/1V5_EPS_TS_SYSTEM_112: External interfaces – Mechanical interfaces

The product shall have interfaces which resist to component stresses in mechanical interface (Subframe, column
and knuckles).
Validation test: PSA validation:

- fatigue of the mechanism interface on subframe,
- fatigue of tie rod ball joint interface on knuckles
 BMPV/1V5_EPS_TS_SYSTEM_113: External interfaces – EE interface

The product has to Communicate with the Components in EE interface.
Reference: Inter-system TS [A4020]
 BMPV/1V5_EPS_TS_SYSTEM_114: External interfaces – Connections

The product shall include standard connections.

Test sheet N°79
Reference: DAE Hardware TS [A003]

Functional drawing [A4010]
 BMPV/1V5_EPS_TS_SYSTEM_0115: External interfaces – Configuration downloading loading

Parameters sets shall be downloaded in the ECU at the end of PSA line.

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5.4 OPERATIONAL REQUIREMENTS
5.4.1 Mission profile
 Duration of the mission: 15 years
 Total number of run km: 240 000 km
 Operating time (power on): 7 500 hours
 Number of system activation cycles: 120 000
 Number of STTa/STTd cycles: 540 000
 Duration of maximal continual stress: TBD

 Maximum effort (curb push away): refer to the paragraph 6.1.2
 Generic constraints
The power steering mechanism should be able to operate normally in the following using field:
 steering wheel speed varying from 0 to 1 440°/s
 steering wheel acceleration varying from 0 to 100 000 °/s²
 vehicle speed varying from 0 to 70 m/s
 acceleration or deceleration varying from 0 to 15 m/s²
 Thermal profile
The following tables determine the exposure durations of the system in the power train compartment by
high and low ambient temperatures.
Reference BMPV
TminHF = -40°C
TminEF = -30°C
Tmoy = 90°C
TmaxEF = 110°C
TmaxHF = 110°C
Reference 1V5
TminHF = -40°C
TminEF = -30°C
Tmoy = 90°C
TmaxEF = 110°C
TmaxHF = 130°C
Option 3
Tmin HF =-40°C
Tmin EF = -30°C
Tmoy = 100°C
Tmax EF = 120°C
Tmax HF = 130°C
The file [A1118] provides a skin temperature estimation for the operating points indicated above. It should be noted
that these estimations do not take into account the thermal conduction that could appear on the metallic type parts
and whose surface exposed to radiation is important.
5.4.2 Ergonomics and human factors

 BMPV/1V5_EPS_TS_SYSTEM_116: Ergonomics/Human Factors – Protect the operator
The product should not have sharp, cutting edges or projection able to injure an operator or a customer. The
product shall not contain materials harmful for the operator.

 BMPV/1V5_EPS_TS_SYSTEM_117: Ergonomics/Human factors – Assembly ergonomics

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The product has to meet the ergonomics rules (comply with the working legislation, especially for its installation
on vehicle):
- Marking
- Diversity
- Installation efforts (example: if the product weight is higher than 8kg, the supplier commits to work in
collaboration with PSA to define an installation help system (switch)).
- Gripping (obvious gripping area)
- Kinematics for installation

Test sheet N°08
 BMPV/1V5_EPS_TS_SYSTEM_118: Ergonomics/Human Factors – Weight
The weight of the product (whole power steering system including the functional assistance module, fastenings, tie
rods, harness and connections) has to be lower than 11 kg for BMPV and 9,7kg for 1V5

 BMPV/1V5_EPS_TS_SYSTEM_119: Ergonomics/Human Factors – Tightening
The final tightening of tie rod locknuts should be done without lock wrench. The tightened components, tie rod
locknut, knuckle ball joint and subframe fastening, shall allow a minimal tolerance of +/- 10 % relatively to their
tightening value (whether it is determines by PSA or the supplier). For the tie rod locknut, the tightening torque
could not be above 60 Nm for ergonomic constraints.
Validation test: Supplier test (The supplier has to justify the performance of these tests)
 BMPV/1V5_EPS_TS_SYSTEM_120: Ergonomics/Human Factors – Rack position
The rack has to arrive in the terminal plant in « rack zero » position (middle of the total travel +/- 0,75 mm) and
with the preset tie rods, with a tightening in position. The tightening torque has to be easily « untightenable » (10
N.m maxi).
 BMPV/1V5_EPS_TS_SYSTEM_121: Ergonomics/Human Factors – Supplier installation instructions
The supplier has to indicate on the drawing his own instructions for the product installation on vehicle.
 BMPV/1V5_EPS_TS_SYSTEM_122: Ergonomics/Human factor - Harness coiling and termination
protection
The termination of the harness connection shall be protected. The protection device shall be visible by the
operator (color differentiate related to the connector color). This unique device shall be easily removable by only
one operation and shall contribute alone to coil the harness in its plant delivery position. The supplier shall provide
to PSA during the quotation phase and the development phase a 3D model representative of the coiling of the
harness
Validation test : Digital validation
 BMPV/1V5_EPS_TS_SYSTEM_123: Ergonomics/Human Factors – handling device compatibility

The supplier shall let free an area for the handling of the part. This area is defined in the functional drawing [A4010]
Reference : PSA functional drawing [A4010]
5.4.3 Product quality

APPEARANCE
 BMPV/1V5_EPS_TS_SYSTEM_124: Product quality – Appearance
The study of the system has to reveal:
 The presence of all the elements composing the assembly in compliance with the drawings,
 The presence of crimping, welds, coatings, grease...
 The absence of edge crack, impact trace, rack boot incipient tear or tear, lubricant leakage ...

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The parts have to be free from visible defects, impacts or mutilation, oxidation traces, burrs, tears,
The parts shall present interface surfaces free from smears, burrs, chips, paint, etc.
Every system which has suffered an impact has to be rejected for safety (non-visible degradation risk).
QUALITY OBJECTIVES
 BMPV/1V5_EPS_TS_SYSTEM_125: Product quality – Quality Objectives
The Supplier has to meet the quality requirements.
Reference: Document of quality Objectives [A1110].
5.4.4 Protection against malicious intent

Not applicable
5.4.5 System resources

Not applicable
5.4.6 Documentary requirements

 BMPV/1V5_EPS_TS_SYSTEM_126: Documentary requirements
The Supplier engages itself to provide the documents indicated in the CPPR document [A1030].
Reference: CPPR [A1030]
5.4.7 Mass production evolution

 BMPV/1V5_EPS_TS_SYSTEM_127: Documentary and approval of a mass production evolution
During the mass production, the supplier shall submit to PSA by the way of a FETE each evolution of product and
process. Those evolutions are classified in the followed standard. Then for each category, PSA has defined all the
deliverables that the supplier shall transmit to PSA for the approval of this evolution.
Reference : Gestion des évolutions vie série DTI_DQI08_0020 [A1022]

Standard - Gestion des évolutions VS d'origine fournisseur [A1023]
5.5 CONSTRAINTS REQUIREMENTS

5.5.1 Regulatory and consumerism
 BMPV/1V5_EPS_TS_SYSTEM_128: Regulation
The supplier has to ensure that the product meets the regulations of the countries where the product is sold (the
drawing type documents, FMEA, Failure Trees… should show the regulatory standards).
5.5.2 Weight and other physical characteristics

See 5.4.2 Ergonomics and human factors

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5.5.3 Design and production
STUDIES AND/OR IMPOSED SOLUTIONS
 BMPV/1V5_EPS_TS_SYSTEM_129: Design – Connecting tie rods
Shapes, overall dimensions and capacities of ball joints and fasteners have to be compliant with the
characteristics indicated in the functional drawings.
 BMPV/1V5_EPS_TS_SYSTEM_0130: Design – Parallelism adjustment

The mechanism has to be preset at a dimension L which has to be indicated on the drawing and allow an
adjustment of +/- 6 mm.
 BMPV/1V5_EPS_TS_SYSTEM_131: Design – Maximal clearance between tie rod/ball joint on knuckle

side
Each tie rod with the ball joint on knuckle side fixed by its threading has to have a maximal clearance equal to:
 1 mm along the NM axis under an effort of +/- 250 daN,
 BMPV/1V5_EPS_TS_SYSTEM_132: Design –tie rods sizing

The sizing of the steering tie rods has to be performed according to the Appendix 1: Unusual efforts.
Validation test: Vehicle test
PRODUCT MARKING
 BMPV/1V5_EPS_TS_SYSTEM_133: Marking – EMC R
The controller should have an EMC approved marking reference:

-- On product label
and
-- On diagnostic data frame
 BMPV/1V5_EPS_TS_SYSTEM_134: Material marking
The marking of parts shall respect the B20 0110 PSA standard [A3046]
The plastic material parts are marked according to the standard B20 1315 [A3054] and in compliance with the
guideline CE 2003/13/138 [A2040].
The elastomer parts are marked according to B20 1415 [A3056] and in compliance with the guideline
CE 2003/13/138 [A2040].

CE Standard 2003/13/138 [A2040]
 BMPV/1V5_EPS_TS_SYSTEM_135: Protection against bogus

The product has to be marked with the PSA logos (Peugeot, Citroën): A10 2260 [A3010].
Reference: PSA Standard A10 2260 [A3010]

01452_13_00009 BMPV / 1V5 61/178
5.5.4 Traceability and configuration monitoring
PRODUCT IDENTIFICATION
 BMPV/1V5_EPS_TS_SYSTEM_136: Product identification – Bar code

The steering mechanism is marked individually with a 2 sections self-adhesive label with double supports:
Couleurs: etiquette blanche Colours: white label

Inscriptions noires Black inscriptions
Moitie detachable Removable half part
Moitie collee Stuck half part
№ serie Serial no.
- bar code type 39, from 6 to 8 characters per inch (height: minimum 10 mm, optimized-reading)
- alphanumeric code in clear text (height: minimum 5 mm)
- PSA number (height: minimum 3 mm except characters from 6 to 8 which have to be bigger in bold type,
minimum 5 mm)
- PSA index (height: minimum 3 mm)
Bar code content:
Nature Nature
Repère Organe Component Reference
Séquence Numérique Digital Sequence
Characters 1 and 2: component family (60 for the steering)
Characters 3 to 6: component reference ((bijective correspondence between the component reference and the
product number), alphanumeric characters except the characters I and O. The 2 first characters are kept to
identify the component supplier. The 2 followings correspond to the product number.
Characters 7 to 13: chronologic digital sequence of the part production. It is associated with the component
reference.
If this number is lower than 7 characters, place it on the right and complete by 0.
Reference: Q_P185130_01 [R1080]
 BMPV/1V5_EPS_TS_SYSTEM_137: Product identification – Label

The label shall be firmly stuck on the mechanism and has to be indelible during the product lifespan. This label
shall be easily readable by a scanner without moving or rotating the part.

01452_13_00009 BMPV / 1V5 62/178
Validation test: Include the label in the environment tests (system test sheet)
Digital validation of the label
 BMPV/1V5_EPS_TS_SYSTEM_138: Product identification – Traceability

The following traceability data has to be indicated in the controller and available on request:
Type de composants Type of components

Informations à enregistrer Information to be recorded
№ de série Series No.
Date de fabrication Production date
Références (hard, soft et Dote) References (hard, soft and Dote)
Fournisseur (code fournisseur) Supplier (supplier code)
Type de Traçabilité Type of traceability
Composants à traçabilité renforcée Components with reinforced traceability
Facultatif Optional
Obligatoire Mandatory
Lot de fabrication + FNR Production batch + SPR

Q_185132 [R1090]
5.5.5 Transportability and conditioning

TRANSPORTATION MEANS AND CONDITIONING
 BMPV/1V5_EPS_TS_SYSTEM_139: Transportation – Absence of product degradation
The product should not undergo any degradation (of appearance, of adjustment, dimensional, functional,…) until
the delivery.
For this, the product has to be able to resist to the transportation, handling and loading conditions. The fragile
areas have to be protected (ball joint tail, stud, connector …).
Validation test: Transportation test on final container

 BMPV/1V5_EPS_TS_SYSTEM_140: Transportation – Product assembly resistance
No part has to dissociate itself from the product during transportation. (Studs, Nuts, Screws,…): the stud
tightening torque before the assembly has to be indicated on the drawing.

 BMPV/1V5_EPS_TS_SYSTEM_141: Transportation – Conditioning development
The supplier shall commit to contribute to the conditioning development by the supply of physical and digital
models.
 BMPV/1V5_EPS_TS_SYSTEM_142: Transportation – Compatibility of harness/container

The harness coiling has to be consistent with the container.
Validation test: static and dynamic test

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 BMPV/1V5_EPS_TS_SYSTEM_143: Transportation – Optimization of the conditioning
The product has to contribute to the optimization of the conditioning:
 Limit the conditioning diversity
- The product has to be easily self-conditioned in standard boxes
 BMPV/1V5_EPS_TS_SYSTEM_144: Transportation – Impact

The product has to keep its mechanical and physico-chemical characteristics in case of impact until the threshold
defined in the M3.1 and M3.3 tests.
Validation test: Test sheet N°75 (B21 7120/M3.1 Ball fall)

Test B21 7120/M3.3 Free fall
SUPPLY APPROVAL
 BMPV/1V5_EPS_TS_SYSTEM_145: Supply approval
No defect should be accepted at delivery; all parts with defect should be returned to the supplier.
The product has to be delivered assembled, lubricated and be easily packaged.
The product should be validated only after the homologation of the complete function on vehicle by an official
institution in compliance with the different regulations
5.5.6 Flexibility and extension

 BMPV/1V5_EPS_TS_SYSTEM_146: Flexibility and extension
The supplier, in case of evolution of its design definition, should inform PSA before the implementation of the
modifications (component ageing, improvement of its design,….).
PSA should give the authorization for the definition change and, according to the modifications, has to allow an action plan
compliant with PSA’s schedule.
5.5.7 Maintenability
 BMPV/1V5_EPS_TS_SYSTEM_147: Maintenability
The supplier has to give and justify the following information about the product:
- The particular facilities needed for the maintenance (proficiencies, tooling equipments),
- The operational conditions to maintain the system.
During the vehicle warranty period, in case of steering system malfunction, the supplier should ensure the
complete service operation.
The component manufacturer should suggest a strategy of maintainability / repair capability to PSA to reduce the
after-sale cost.
Especially, it has to be possible to replace separately:

- inner tie rod
- outer tie rod
- rack boots+brackets
These components should not be matched.

01452_13_00009 BMPV / 1V5 64/178
5.5.8 Materials
SERVICE REMOVAL
 BMPV/1V5_EPS_TS_SYSTEM_148: Regulation and consumerism R
The requirements of the B20-0200 standard specifying the part’s end of life treatment obligations according to the
European directive 2000/53/CE relating to end of life vehicles (VHU) are to be abided by.
Reference: Guideline 2000/53/CE [A2010]

 BMPV/1V5_EPS_TS_SYSTEM_149: Green materials
As required at vehicle level, the product has to include an increasing part of «green materials» that have a
positive impact on the environment according to PSA standard A12 5200 [A3020].
The green material family contains:

-- Recycled materials: the eligibility for the "recycled" designation is defined in standard ISO 14021 [R4011].
-- Modified natural organic materials and natural fibers: wood, leather, natural fibers (sound insulation / textiles /
reinforced plastic material).
-- Biopolymers: bio-based polymers, i.e. polymers which do not come from the petrochemical industry but from
"renewable" resources (rape, sunflower, beetroot, cane...)
The supplier shall IMPERATIVELY make a proposal that includes green materials. Depending on the application,
a classic proposal (RMA material for the plastics, …) can also be proposed as an alternative
The supplier shall detail to PSA the advantages and potential new constraints involved by the green materials
that are proposed.
Reference: PSA Standard A12 5200 [A3020]

Standard ISO 14021 [R4011]
PLASTIC MATERIALS AND RUBBER

The list of deliverables dealing with plastic materials and thermo-plastics is included in ENCLOSURE 4, § 6.4.2
DOCUMENTARY REQUIREMENTS
 BMPV/1V5_EPS_TS_SYSTEM_150 : Requirements on supplier drawing

The supplier shall include the following items on the supplier drawing
1. The reference of this document,
2. The detailed nomenclature of the component containing at least the following information:
 The chemical nature of materials according to standards B62 0020 for plastics and B63 0020 for
rubber,
 The full commercial reference (including color code) of materials for plastic elements and the mix
reference for rubbers elements,
 The specific STL or the PSA number if they exist, otherwise coding according to B62 0300.
3. An exploded view of the composing elements,
4. The level of cleanliness according to ISO 16 232 if specified,
5. For elements made of TP, the localisation of impact points and the associated shock test weight level
(material integrity see BMPV/1V5_EPS_TS_SYSTEM_166).
According to the application criticality, PSA has the right to require that the nomenclature be completed by
information coming from the materials list

01452_13_00009 BMPV / 1V5 65/178
Reference :
ISO 1629 [A2085]
 BMPV/1V5_EPS_TS_SYSTEM_151 : Additional material & process documents

A material and process nomenclature according standard B20-0050 must be provided when answering to the
RFQ then update version during the development.
Reference : PSA Standard B20 0050 [A3045]
 BMPV/1V5_EPS_TS_SYSTEM_152 : Manufacture flow chart

In response to the RFQ, the supplier shall provide a detailed manufacture flow chart for the organic materials
elements. Tier 2 and other supplier levels shall also appear on the chart.
Examples :
- Manufacturing process: injection molding, extrusion, extrusion blowmolding, etc.
- Assembling: welding (IR, US, vibration, etc.), glueing, hafting, etc
 BMPV/1V5_EPS_TS_SYSTEM_153 : Compliance certificate for organic materials

The supplier shall provide a compliance certificate of all organic materials. This must at least contain the
following information:
- The full commercial reference for plastics or the mix reference for rubbers
- The chemical nature of the polymer
- The rate and chemical nature of reinforcements or fillers
- The density
- The viscosity
- The moisture content of packaged granulates (only for the moisture sensitive plastics like PA, PBT, etc.)
- The hardness (only for rubbers)
 BMPV/1V5_EPS_TS_SYSTEM_154 : Process Parameters

For all elements made of TP, TPE or thermoset, the supplier must fill the appendices of the B20 1310 [A3053]
standard concerning its manufacturing process
 BMPV/1V5_EPS_TS_SYSTEM_155 : Rheological study

In addition to the documents requested by PSA component conception teams, the justification documents of the
supplier shall contain a rheological study, which justifies:
- The location of the injection point(s)
- The material quality in terms of porosities, residual strains and shrinkage
 BMPV/1V5_EPS_TS_SYSTEM_156 : Mechanical resistance design study

In addition to the documents requested by PSA’s component design teams, the justification supplier’s documents
shall contain a mechanical resistance design study, which shall include the following information:
- The details of the material data used in calculation and their origin
- The justification of the acceptance criteria(s)
CONSTRAINT REQUIREMENTS ON MATERIAL
 BMPV/1V5_EPS_TS_SYSTEM_157 : B62 0300 Standard

01452_13_00009 BMPV / 1V5 66/178
All materials shall fulfill the requirements in standard B62 0300 according with their environment.
Conformity Heavy metals 61
Exposition to the ambient air (resistance to

52
ozone)
Exposure to heat * 209M / 211E
Behavior to the permanent contact with fluids* H709
Exposure to a chemical environment 13
Satisfy the combustibility requirements C1 (1)
Elasticity at compression * P+209M / P211E
Elasticity at traction * L211E

(1)
except particular requirement specified on the drawing (ex: V0)
Remarks for electronic components: The range of mean and peak temperatures for components subject to
self heating (PCU, …) shall be defined according to Test n°62 (CL06). By default the supplier shall take into
account the values inside the chart.
The supplier shall perform the most adapted characterization (traction and/or compression) according with the
function of the component. (ex: rack boots rather in traction, air tightness rather in compression)
Case of rubbers and TPE :

The supplier shall propose materials allowing to fulfill the functional requirements of the part or the function, by
taking account of specificities of each material family. The code of material requirements will have to be
completed by the supplier according to the standard B62 0300 :
- Codes J (hardness),
- M1 mini to be characterized by the supplier (tear strength),
- Q (elongation at break),
- R (tensil strength) to be notified on drawing cold behavior : K3,
- stiffness in cold situation* K4
- Trend to cold crystallisation (ex CR, NR…) : X1 (see doc [A003])
For all the parts like seals, rack boots, etc., the use of mixture containing nitrile (NBR) is forbidden.
*These requirements can be adjusted according to the functional schedule of conditions of the project conveys
considered (thermal stress, fluid contact,…)
 BMPV/1V5_EPS_TS_SYSTEM_158 : Choice of materials

The chosen materials have to be validated by the PSA material and processes department, before that
prototype or serial tool production were launched.
The decision to establish a SPA or not is made during the initialization review, or later in the case of a technical
incident during development or serial production.
According to PSA material policy, the material choice (for TP, TD & TPE) shall be done according to the
following rule, in the following order of priority:
1. Propose a material listed in the RMA (only for TP and TPE). See list on the B2B portal
(library/consultation/topic/development/materials vhl : RMA list
2. If no material listed in the RMA corresponds with the function: propose a material with a SPA (consult the
01452_13_00009 BMPV / 1V5 67/178
raw material producers or rubber manufacturers)
3. If no material listed in the RMA or with a SPA corresponds with the function: propose a material from a
raw material producer belonging to the PSA material panels (only for TP and TPE). See panels on the
B2B portal: bibliothèque / consultation / thème / développement / matériaux vhl : panel
4. If no material listed in the RMA or with a SPA or coming from a PSA panel producer corresponds with
the function: propose a material from another producer. Such a choice must be technically and/or
economically justified.
This rule shall be applied to Tier 1 and other supplier levels.
 BMPV/1V5_EPS_TS_SYSTEM_159 : Rubber Transversal resistivity

In case of a black rubber part in contact with metallic parts (even if coated*) located in moisture retention zone of
the vehicle (under the chassis, aero thermal front, wheel housing, lower engine parts, blow-by circuit, etc.), the
material volume resistivity (according ISO 14309 standard) must be strictly higher than 10 9 Ohm.cm for contact
with magnesium and strictly higher than 108 Ohm.cm for contact with all other metals (in order To be avoided
galvanic corrosion phenomenon).
(*): metallic coating or painting if degradation (gravelling, abrasion) can occur.
Reference : Standard ISO 14309 [R4012]
 BMPV/1V5_EPS_TS_SYSTEM_160 : Requirement concerning adhesive assembly

Requirement concerning adhesive assembly according B20 4100 standard
Exterior application
Initial adhesion of bonding 8
Resistance to water 8
Climatic ageing 8
Resistance to chemical agent 8
Functional requirements Cf validations tests
Reference : Standard PSA B20 4100 [A3057]
Validations : Test sheet N°20

Test sheet N°21
Test sheet N°22
Test sheet N°63
Test sheet N°64
Test sheet N°70
Test sheet N°71
Test sheet N°74
Test sheet N°102
Sequence A, C, D, E, H, I
 BMPV/1V5_EPS_TS_SYSTEM_161 : Material compatibility (rustled noise)
The component supplier shall make sure that the proposed materials on the parts are not likely to generate
audible noises when they are in contact between each other. Specific tests will be required in order to validate
this requirement.

01452_13_00009 BMPV / 1V5 68/178
 BMPV/1V5_EPS_TS_SYSTEM_162 : Product for assembling
The supplier shall provide the list of chemical composition of additional products used to help the assembling
that are not compatible with the application.
Example for a hose in EPDM material: recommendation to be given to PSA: no assembling helping product that
include mineral oil
MATERIAL REQUIREMENTS
 BMPV/1V5_EPS_TS_SYSTEM_163 : Sampling of validation parts

For the validation tests, the following parts shall be used:
- Parts taken from a conform batch
- Parts containing the highest rate of reground material (declared in the detailed material nomenclature
BMPV/1V5_EPS_TS_SYSTEM_150)
- Parts having the lowest weight
For parts made of moisture sensitive TP (like PA, PBT, etc.), the tested part have to be conditionned according
to NF EN ISO 1110 before the validation test is performed.
Reference : Standard NF EN ISO 1110 [A2090]
Foreword:
The list of the technical characteristics to be checked on parts must be given according to following straight edge:
1. To break up the part into elementary components. (example for an EPS: housing + reduction gear +
connection box + …)
2. For each element, to respect the requirements of the STL or specific standard if it exists.
3. In all the cases, to respect each requirement of the signaling station below, except if there is already one in
the functional schedule of conditions of part (ST, STN, functional drawing…).
 BMPV/1V5_EPS_TS_SYSTEM_164 : Technical characteristics on parts
For all parts in TP, TD, TPE or rubber, the supplier shall guaranty the absence of defects coming from material
processing.
Acceptability criteria
Absence of surface defects: shrinkage, cracks, grilled, bubbles, lack of material, pollution, etc.
Porosity level (or bubble for rubbers)
The acceptance criteria for the porosity level will be validated by the PSA material department, considering
the severity of the element (complexity and mechanical loading).
In any case, even if the component responds to its function, the following defects are unacceptable:
- Porosity size >= 500 µm
- More than 20% of the thickness affected by porosities.
- Porosity shape too elongated (length / width > 4)
Absence of internal defects: welded line mark, pollution, cluster of fillers, traces of flows, etc.
Weight : Differences between parts shall be lower than 5% (i.e. 2,5 % compared to the average value)
Hardness : according to ISO 48 or D10 5010
During the whole serial production phase, the supplier must supply parts with an internal integrity being
better or at least equivalent to the integrity of the validation parts.
Reference : Expert procedure : CIMB_IMPM09_0286

PSA standard : D10 5010 [A3082]

01452_13_00009 BMPV / 1V5 69/178
Standard ISO 48 [R4013]
 BMPV/1V5_EPS_TS_SYSTEM_165 : Evaluation of material quality – Welded elements

Acceptance criteria :
The acceptance criteria for the welding bead will be validated by the PSA material department, considering the
criticity of the element (complexity and mechanical loading).
The following items shall to be analyzed:
- Presence of burrs
- Burr symmetry on both extremities of the bead.
- Width of the bead / coverage ratio of welding teeth
- Thickness of the welding bead.
There shall be no porosity in the welding bead
 BMPV/1V5_EPS_TS_SYSTEM_166 : Behavior in case of impact (plastic elements)

The components made in material TP, TD or TPE shall define the resistance threshold upon impact as specified
in the PSA standard D42 1235 [A3081].
Impact points are to be determined in agreement with the PSA materials department and have to be located in
welded and fragile zones (welding bead, clip, small thicknesses, injection point, etc.).
The rupture level upon impact corresponds to the maximum weight of the dropped object creating no rupture
with 50cm/-30°C/ object A or 50cm/23°C/ object B
This maximal weight shall be higher than 200g at 50cm/-30°C/object A.
Reference : PSA standard D42 1235 [A3081]
 BMPV/1V5_EPS_TS_SYSTEM_167 : Architecture of multi-material parts

Acceptation criteria:
To meet the component definition: quality and quantity of composing elements, thicknesses, positioning,
bonding, etc.
 BMPV/1V5_EPS_TS_SYSTEM_168 : Contact with occasional fluids

The aim of this requirement is to check the process impact on the material compatibility to fluids
The tested element shall keep its integrity after the test :
- No deterioration (cracks, swelling, partial dissolving, etc.), no aspect change.
- The component must remain functional (mechanical resistance and dimensional conformity).
Reference : PSA standard D47 1924 C process [A3087]

PSA standard B71 6000 [A3067]
Validation test : Test sheet N°51

Test sheet N°52
Test sheet N°61
 BMPV/1V5_EPS_TS_SYSTEM_169 : Resistance to thermal ageing (at peak temperature)

The aim of this requirement is to validate the thermal ageing resistance of the plastic and rubber components

01452_13_00009 BMPV / 1V5 70/178
- Absence of aspect change or deformation.
- Comply with the dimensional tolerances defined on the functional drawing.
- The component must remain functional.

Validation tests : Test sheet N°80
Test sheet N°20
Test sheet N°21
Test sheet N°102
 BMPV/1V5_EPS_TS_SYSTEM_170 : Resistance to thermal ageing (at continuous use temperature)

The aim of this requirement is to validate the thermal ageing resistance of the plastic and rubber components
- Absence of aspect change or deformation.
- Comply with the dimensional tolerances defined on the functional drawing.
- After the test, the component must remain functional and the rupture level with impact testing must
remain the same.


Test sheet N°20
Test sheet N°21
Test sheet N°102
 BMPV/1V5_EPS_TS_SYSTEM_171 : Resistance to thermal shocks

The aim of this requirement is to determine the effects of the differential thermal expansion
This requirement is applicable for Multi-material components (overmoulded, glued, screwed, etc.) and welded
elements
- Absence of cracks upon observation with magnifying binocular glass (X10).
- After the test, the component must remain functional.

Test sheet N°63
Sequence E
 BMPV/1V5_EPS_TS_SYSTEM_172 : Climatic cycles

The aim of this requirement is to determine the effect of the differential thermal expansion + humidity pick-up
and/or hydrolysis checking
This requirement is applicable for Multi-material components (overmoulded, glued, screwed, etc.) and welded
elements and elements made of moisture sensitive materials (PBT, PA, PUR, etc.).
- Absence of cracks upon observation with magnifying binocular glass (X10).
- After the test, the component must remain functional.

01452_13_00009 BMPV / 1V5 71/178
The technical requirements of this standard are to be checked for the integration & validation of the part.
In addition, conformity to requirements BMPV/1V5_EPS_TS_SYSTEM_163, BMPV/1V5_EPS_TS_SYSTEM_164,
BMPV/1V5_EPS_TS_SYSTEM_165 et BMPV/1V5_EPS_TS_SYSTEM_166 is also to be surveyed in serial
production, with a frequency to be determined by the supplier.
METALIC MATERIALS
 BMPV/1V5_EPS_TS_SYSTEM_173 : List of metallic materials and processes
The supplier shall fill-up the list of materials and processes items during the RFQ phase for all the components in
compliance with PSA Standard B20 0050
Reference : PSA standard : B20 0050 [A3045]
 BMPV/1V5_EPS_TS_SYSTEM_174 : Supply of metallic materials

The supply of metallic material designed for forging, extruding and casting process shall comply with PSA
standard B20 1220.
Reference : PSA standard : B20 1220 [A3052bis]
 BMPV/1V5_EPS_TS_SYSTEM_175 : Material for casting

All materials used in casting procesess shall comply with the global and metallic materials requirements of the
PSA standards.

NF EN 1561 [A2081]
NF EN 1563 [A2082]
BMPV/1V5_EPS_TS_SYSTEM_176: Parts in aluminum and alloys

Aluminum alloys used on the part shall comply with PSA Standard B54 1120

NF EN 1706 [A2083]
NF EN 1780-2 [A2084]
 BMPV/1V5_EPS_TS_SYSTEM_177: Galvanic coupling and free potential

All couples of intermetallic material or metallic/rubber material shall comply with the following requirements in
order to avoid galvanic corrosion:
- the potential difference between the two material shall be less than 300 mV
- the transversal resistivity of the rubber shall be over 108 Ω.cm
These couples shall be measured in compliance with the standard D13 5510
Reference : PSA standard: D13 5510 [A3068]
 BMPV/1V5_EPS_TS_SYSTEM_178: Analysis of new parts

The analysis of new parts is indispensable and compulsery in order to:
- Determine the weak points of the function
- Ensure the compliance of the part with the drawings
- Determine the quality of the process (cleanliness, defect due to manufacturing process)
- Be used as a reference in case of a customer or driving test issue
- The analysis of a new part is required before any validation.The part used for the analysis must come from the
same batch as the part used for the validation.
Reference : CPBM_CMPM06_0087 [A4110]
 BMPV/1V5_EPS_TS_SYSTEM_179: Coating qualification for steel parts

01452_13_00009 BMPV / 1V5 72/178
The coating qualification and its quality must be done. The supplier shall follow the PSA standard : D17 1058 in
order to make these tests
Reference : Standard D17 1058 [A3075]
 BMPV/1V5_EPS_TS_SYSTEM_180: Coating qualification for aluminum parts

The airtightness and the watertightness shall be tested by a SWAAT test of 750h or 1000h, depending on the
risk (each modality is described in the following document CIMB_IMPM09_0458). SWAAT test is standardized
by the ASTM G 85 Appendix 3. This test is used to :
- determine the cinetic of aluminium corrosion
- qualify the airtightness and watertightness of the part
Reference : ASTM G 85 Annexe 3 [A2080]
 BMPV/1V5_EPS_TS_SYSTEM_181: Galvanic coupling qualification

On the global part (all elements of the part assembled) BS test must be done, in compliance with the PSA
standard D17 1058, in order to identify any galvanic corrosion risks.
Reference : PSA Standard D17 1058 [A3075]
 BMPV/1V5_EPS_TS_SYSTEM_182: SPA / STL

Some parts of the system might be submit to the PSA standard B21 0150 which deal with the specification of
approval product (SPA)
If housings are made through an aluminum or iron casting process. A SPA must be built for these parts.
 BMPV/1V5_EPS_TS_SYSTEM_183: Testing method for flat product material appraisal

The different methods for metallic appraisal are describe into the PSA standard B53 3055. The supplier should
commit to these methods. In the contrary case, the supplier should be able de externalize these tests or he
should delivered the standard that he use else describe these internal methods for the different test, so as to
evaluate the comparability of PSA results and Supplier results

01452_13_00009 BMPV / 1V5 73/178
5.6 INTEGRATION AND VALIDATION REQUIREMENTS
5.6.1 Validation drawing
 BMPV/1V5_EPS_TS_SYSTEM_184: Validation - Validation plan
The supplier has to establish a validation plan which has to guaranty the product / process design of the product.
5.6.2 Development sessions

BMPV/1V5_EPS_TS_SYSTEM_185: Validation - Development sessions
The supplier commits itself to participate to the vehicle development tests. For information, the development
duration for all car types, which compose the 1st batch, is 30 weeks.
Validation test: development on vehicle
5.6.3 Validation tests

GENERAL INFORMATION
The tests explained in this document are those recommended by PSA to verify the technical specification
requirements. The supplier, as an expert, can suggest evolutions or additional tests which have to be submitted to
PSA for approval before their integration in the validation plan.
The efforts indicated in the test sheet correspond to the most critical vehicle (MTAC_Av Maximum, Maximal
pneumatic fit). PSA can provide, if the supplier requests it, other effort values to adjust the validation plan to the
EPS declination.
Before and after each test sheet, all EPS have to checked by DTC reading : EPS shall be functional without any
modification of the electric and electronic characteristic.
During each test, the supplier shall store the electrical data (Voltage at the end of the harness, and Intensity
consumption of the ESP) related to time.
All requirements have to be met with a single configuration file.

The supplier has to include in his own test procedure the tightness qualification and quantification. Such
qualification could be done by adding a water tracer component (for ex. fluorescein).
TEST CONDITIONS (UNLESS OTHERWISE INDICATED)

Unless otherwise indicated in the test sheets:
 1 for each speed = 10km/h
Vehicle speed
 5 for each speed > à 10 km/h
Efforts  10 daN
The mechanism has to be attached by its fasteners on a rigid support.

Tightening torque of the mechanism fasteners 100 Nm +/- 10%
Tightening torque of the knuckle ball joints 35Nm +/- 10%
To be specified by the supplier (ergonomics target =60Nm +/-
Tightening torque of the tie rod nuts
15%)
*In case of a difference between the above values and the drawing, it is the value indicated on the drawing which is
used.
Midpoint: this is the middle of the rack travel. To determine it, the operator has to measure the total travel (+/- 1
mm) from one end to another then apply the ½ travel (+/- 0.5 mm) from one rack end stop.

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LIST
Numbers
No. of parts
Title Requirements
Tests
Proto IOD
BMPV/1V5_EPS_TS_SYSTEM_03: Assistance – Tolerance
on the assistance laws
BMPV/1V5_EPS_TS_SYSTEM_04: Assistance – Asymmetry
No.01 Assistance law measurements
of assistance laws
BMPV/1V5_EPS_TS_SYSTEM_05: External constraints –
Water tightness and air tightness after thermal shock
BMPV/1V5_EPS_TS_SYSTEM_06: Assistance – smooth
No.02 Assistance variation
evolution of the assistance torque
BMPV/1V5_EPS_TS_SYSTEM_07: Performance related to
the steering wheel speed [Nominal voltage]
the steering wheel speed [STT mode]
Water tightness and air tightness after thermal shock
BMPV/1V5_EPS_TS_SYSTEM_010: Interface – Onboard
power supply Voltage
Performances related to the steering
No.03 wheel speed, ambient temperature and
Power supply voltage range
BMPV/1V5_EPS_TS_SYSTEM_013: Assistance performance
= f(T°C, voltage) @ steering wheel speed <= 360 °/s
= f(T°C, supply voltage) @ steering wheel speed = 480 °/s
= f(T°C, voltage supply) @ steering wheel speed = 720 °/s
BMPV/1V5_EPS_TS_SYSTEM_016: Assistance torque
Assistance performance depending on related to the rack travel [Nominal voltage]
No.05
the rack travel BMPV/1V5_EPS_TS_SYSTEM_017: Assistance torque
related to the rack travel [STT mode]
BMPV/1V5_EPS_TS_SYSTEM_018: Thermal performance –
Rack End hold
No.06 Thermal protection performances
Effort constraint
Thermal peak PTR2
BMPV/1V5_EPS_TS_SYSTEM_021: Sliding effort and effort
No.07 Mechanical friction
variation
BMPV/1V5_EPS_TS_SYSTEM_22: Ergonomics/Human
factors – Assembly ergonomics
No.08 Weight
BMPV/1V5_EPS_TS_SYSTEM_23: Ergonomics/Human
Factors – Weight
BMPV/1V5_EPS_TS_SYSTEM_0024: Transmission of the
No.09 Ratio efforts
BMPV/1V5_EPS_TS_SYSTEM_0025: Pinion – rack ratio
BMPV/1V5_EPS_TS_SYSTEM_026: Ball joint friction
No.10 Travel and rotational torque
maximum effort
BMPV/1V5_EPS_TS_SYSTEM_027: Acoustic – Radiation
BMPV/1V5_EPS_TS_SYSTEM_028: Acoustic – Blocking
No.11 Acoustic level efforts
BMPV/1V5_EPS_TS_SYSTEM_029: Acoustic – Blocking
efforts / « back-lash » excitation type
No.12 Assembly effort BMPV/1V5_EPS_TS_SYSTEM_030: Assembly – assembly
efforts

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No.13 Break-away effort BMPV/1V5_EPS_TS_SYSTEM_031: Break-away effort
BMPV/1V5_EPS_TS_SYSTEM_0032: No play
BMPV/1V5_EPS_TS_SYSTEM_033: Tightening torque of the
wheel alignment
BMPV/1V5_EPS_TS_SYSTEM_034: Mechanical resistance
variation
No.20 Mixed durability test
BMPV/1V5_EPS_TS_SYSTEM_039: Mechanical resistance –
Maximal, incidental and accidental forces
BMPV/1V5_EPS_TS_SYSTEM_150 : Requirement
concerning adhesive assembly
wheel alignment
variation
No.21 CRD durability
Vibration
No.22 Vibrations strength
No.30 Brackets fatigue on fatigue on subframe fastening on subframe
wheel alignment
BMPV/1V5_EPS_TS_SYSTEM_053: Tie rod Elasticity
No.33 Tie rod fatigue
BMPV/1V5_EPS_TS_SYSTEM_55: Design – Maximal
clearance between tie rod/ball joint on knuckle side
variation
No.40 Impacts test on steering in straight line
No.41 Impacts test on steering at rack end stop
No.42 Impacts test on tie rods Maximal, incidental and accidental forces
BMPV/1V5_EPS_TS_SYSTEM_63: Design –tie rods sizing
No.43 Unusual efforts resistance
Resistance to driver
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No.50 Accelerated corrosion
Corrosion (CCA)
Chemical and atmospheric resistance Aggressive fluids
No.51
(B21 7130/CL25) BMPV/1V5_EPS_TS_SYSTEM_158 : Contact with occasional
fluids
Air tightness and water tightness
Resistance to humidity and corrosion
No.52 Corrosive thermal environment
Corrosive thermal environment
BMPV/1V5_EPS_TS_SYSTEM_158 : Contact with occasional
fluids
BMPV/1V5_EPS_TS_SYSTEM_070: Road feedback – Force
No.53 Information feedback
stress
No.54 Dynamic performances 1 BMPV/1V5_EPS_TS_SYSTEM_071: Inertia feeling
No.55 Dynamic performances 2 BMPV/1V5_EPS_TS_SYSTEM_072: Centering – Hysteresis
BMPV/1V5_EPS_TS_SYSTEM_073: Centering – Hysteresis

No.56 Centering and steering wheel return
BMPV/1V5_EPS_TS_SYSTEM_074: low speed cornering
No.57 Steering stiffness BMPV/1V5_EPS_TS_SYSTEM_075: Steering flexibility
BMPV/1V5_EPS_TS_SYSTEM_076: Assistance – Delay for
No.58 Assistance initialization time
assistance initialization
No.59 Assistance law hysteresis BMPV/1V5_EPS_TS_SYSTEM_077: Hysteresis characterization
BMPV/1V5_EPS_TS_SYSTEM_0078: Transmission of the
Information feedback - Displacement efforts
No.60
stresses BMPV/1V5_EPS_TS_SYSTEM_079: Information feedback –
Displacement stress
BMPV/1V5_EPS_TS_SYSTEM_080: Assistance – Tolerance on
the assistance laws
BMPV/1V5_EPS_TS_SYSTEM_081: Assistance – Asymmetry
of assistance laws
BMPV/1V5_EPS_TS_SYSTEM_082: External constraints – No
degradation of product during 5 years storage duration
BMPV/1V5_EPS_TS_SYSTEM_083: Assistance performance =
No.61 Operating after storage (B21 7130/CL01)
f(T°C, voltage) @ steering wheel speed <= 360 °/s
f(T°C, supply voltage) @ steering wheel speed = 480 °/s
f(T°C, voltage supply) @ steering wheel speed = 720 °/s
BMPV/1V5_EPS_TS_SYSTEM_158 : Contact with occasional
fluids
Self-heating measurement (B21 BMPV/1V5_EPS_TS_SYSTEM_086: Thermal performance –
No.62
7130/CL06) Self-heating
Thermal air/air shocks
Ageing by air/air thermal shocks (B21 BMPV/1V5_EPS_TS_SYSTEM_089: Assistance performance =
No.63
7130/CL07) f(T°C, supply voltage) @ steering wheel speed = 480 °/s
BMPV/1V5_EPS_TS_SYSTEM_150 : Requirement concerning
adhesive assembly
Thermal shock durability (B21 BMPV/1V5_EPS_TS_SYSTEM_091: Thermal cycle durability

No.64
7130/CL08) BMPV/1V5_EPS_TS_SYSTEM_150 : Requirement concerning
adhesive assembly
No.65 Activations durability (B21 7130/CL09) BMPV/1V5_EPS_TS_SYSTEM_092: Assistance performance =

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f(T°C, supply voltage) @ steering wheel speed = 480 °/s
High temperature durability (B21 BMPV/1V5_EPS_TS_SYSTEM_096: Assistance performance =
No.66
7130/CL10) f(T°C, supply voltage) @ steering wheel speed = 480 °/s
Determination temperature operating BMPV/1V5_EPS_TS_SYSTEM_098: Thermal performance –
No.67 Operating limit at temperature
limits (B21 7130/CL11)
Casing protection against solid bodies BMPV/1V5_EPS_TS_SYSTEM_099: External constraints – Air

No.68 tightness and water tightness
(IP5X) (B21 7130/CL13a cat 1)
Casing protection against liquids BMPV/1V5_EPS_TS_SYSTEM_0100: External constraints – Air

No.69 tightness and water tightness
penetration (IPX3) (B21 7130/CL13b)
BMPV/1V5_EPS_TS_SYSTEM_0101: External constraints – Air

Vacuum immersion (IP68) (B21 tightness and water tightness
No.70
7130/CL14)
BMPV/1V5_EPS_TS_SYSTEM_150 : Requirement concerning
adhesive assembly

Thermal shocks with iced water (B21 Water tightness and air tightness after thermal shock
No.71
7130/CL15B) BMPV/1V5_EPS_TS_SYSTEM_150 : Requirement concerning
adhesive assembly

High pressure washing (IPX9K) (B21 tightness and water tightness
No.72
7130/CL16) BMPV/1V5_EPS_TS_SYSTEM_150 : Requirement concerning
adhesive assembly

tightness and water tightness
= f(T°C, voltage) @ steering wheel speed <= 360 °/s
No.75 Ball drop (B21 7120/M3.1) BMPV/1V5_EPS_TS_SYSTEM_0106: Assistance performance
= f(T°C, supply voltage) @ steering wheel speed = 480 °/s
= f(T°C, voltage supply) @ steering wheel speed = 720 °/s
BMPV/1V5_EPS_TS_SYSTEM_0108: Assembly – Degradation
BMPV/1V5_EPS_TS_SYSTEM_109: Transportation – Impact
No.78 Internal connection component test (B21 BMPV/1V5_EPS_TS_SYSTEM_0110: Resistance of the EPS
7120/M1.2) harness connection with the mechanism
No.79 Harness validation BMPV/1V5_EPS_TS_SYSTEM_0111: Electric harness design

No.80 Plastic material ageing related to climatic BMPV/1V5_EPS_TS_SYSTEM_0112: External constraints –
cycle (D47 1309) Corrosive thermal environment
BMPV/1V5_EPS_TS_SYSTEM_156 : Behavior in case of impact
(plastic elements)
BMPV/1V5_EPS_TS_SYSTEM_159 : Resistance to thermal
ageing (at peak temperature)
ageing (at continuous use temperature)
shocks

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BMPV/1V5_EPS_TS_SYSTEM_162 : Climatic cycles
BMPV/1V5_EPS_TS_SYSTEM_0113: Parking stirring [Nominal

voltage]
No.90 Parking stirring
BMPV/1V5_EPS_TS_SYSTEM_0114: Parking stirring [STT
mode]
Steering wheel torque peak during BMPV/1V5_EPS_TS_SYSTEM_0115: Steering wheel torque

No.91
avoidance maneuver during avoidance (dynamic scenarios)
No.99 Electric consumption BMPV/1V5_EPS_TS_SYSTEM_116: Electric consumption -

Measurements
5.6.4 Test sequence

 BMPV/1V5_EPS_TS_SYSTEM_186: Test Sequence
The supplier shall respect the following test sequences on the complete EPS :
Test Sequence
Test sheet
A B C D E F G H (IP1) I (IP2)
N°22 2
N°63 1
N°64 1 1 1
N°65 1
N°66 1
N°68a (underhood) 3 2
N°68b (passenger) 4 3
N°69 3 2
N°70 3 5 3
N°71 2
N°72 4 4
CL07(*) 1 (100) 1 1
CL20 2 2 2
CL21 3 3 3
CL22 4 4 4
Tightness under
pressure 2,5 2 5 5 5
characterization

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Nota :
Test sequence A: Test sheet N°70 could be replaced by an equivalent supplier procedure approved by PSA.
CL07, CL20, CL21 and CL22 are defined according to [A3063].
The supplier shall describe the test procedure of tightness under pressure characterization. It will submitted to PSA
approval.
(*)
The ageing by Air/Air thermal shocks test could be replaced at system level by thermal cycles (CL08),
nevertheless the sequence CL07+CL14 is mandatory at Motor calculator unit subsystem level including the
harness (Moto calculator unit interface).

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5.6.5 Descriptive sheets

N°01: ASSISTANCE LAW MEASUREMENT
OBJECTIVE
Check that the product provides a variable assistance according to the input data.
TEST PARTS
Steering mechanism (including harness)
Power supply
Force sensor
Vehicle signal generator (vehicle speed, engine condition, IGN, etc….)
ASSEMBLY
The mechanism is tightened on a rigid fixture by its fastening at the nominal torque.
The rack is blocked by one tie rod.
LOADS:
For 3 vehicle speeds defined in the parameter tuning file (tuning):
 Min (0 Km/h as a reference) ; medium (80 Km/h as a reference) ; max (250 km/h as a reference)
Starting from the middle position, the column torque (Cc) is swept at a speed of 1.5  0,5 Nm/s.
 From 0 to –10 Nm (counter-clockwise).
 Then from -10 to 10 Nm (clockwise).
 Then from 10 to 0 Nm (counter clockwise).
Note: if necessary, the values of the column torque will be increased to ensure that the entire torque sensor reading
range is used.
Note:
If there is a direct contact between the pinion and the dashpanel joint, a second test has to be performed applying a radial force of 40  0,5 N to
the input shaft at a bearing location.
TARGET
 With the tuning file, the supplier shall plot the theoretical curves (or targets) Fs = f(Cc) and detail the taken
hypothesis in the report (reduction gear ratio, reduction gear efficiency, rack gear ratio, rack efficiency, etc.) as well
as the tuning file used.
o Fs is the rack force in daN
o Cc is the column torque in Nm
 The tolerances are overlaid on the theoretical curves:
o  Cc  1 Nm admissible   0.35 Nm
o  1 Nm Cc 6.5 Nm admissible   0.53 Nm
o  Cc > 6.5 Nm admissible   0.7 Nm
o A maximum right/left dissymmetry of +/-0.3 Nm is allowed.
 For a given output force, the dissymmetry value is determined by : (left column torque –
right column torque)/2
 The measured curves (Fs related to CC) are overlaid.
 The maximum hysteresis shall be represented on the measured curves
 For each vehicle speed, the measured curves must be identical to the target curves (within the
tolerances) Hysteresis values must only be provided for information
 If there is a direct contact between the dashpanel joint and the input shaft, assist laws will not be
disturbed by more than 0.1 Nm when applying the radial force.
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N°02: ASSIST VARIATION
OBJECTIVE
Ensure that the assistance torque evolution related to the vehicle speed variation is smooth and almost unapparent
for the driver.
TEST PARTS
Power supply
Rack force generator
ASSEMBLY
The mechanism is tightened on a rigid support by its fastening at the nominal torque.
The device is associated to a system that creates a constant force called Fsi (see assembly diagram)
STRESS
 The rack output effort Fs should maintained constant.
 A vehicle speed variation shall be simulated by a progressive speed increase (step of 2 kph/s) from Vi to
Vf.(see table below).
 The graph Cc (Nm) has to be plotted with respect to the vehicle speed V.
o The test shall be carried out in two configurations:
Test 1 Test 2
Fs (daN) 400 200
Vi (kph) 0 30
Vf (kph) 20 120

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N°03: PERFORMANCES RELATED TO THE STEERING WHEEL SPEED, AMBIENT
TEMPERATURE AND POWER SUPPLY VOLTAGE RANGE
OBJECTIVE
Check that the product comply with current regulations.
Validate EPS performances.
TEST PARTS
Steering system (including harness)
Electric Power supply system
Vehicle signal emulator (vehicle speed, engine state, IGN, etc….)
ASSEMBLY
The mechanism has to be tightened at nominal torque on a rigid fixture by its fastening.
The mechanism shall be associated to constant force (Fsi) generator device (see assembly diagram).
LOADS
 The mechanism shall be put at the required temperature T° in a climatic chamber.
 The rack is submitted to a stress that corresponds to the required force. The steering wheel speed is kept
constant until the rack end stop is reached (right and left).
 A first test is performed without assistance
 The second test is performed with assistance activated (vehicle speed set to 0 km/h).
o The aim of this test is to check the assist level,
 “comfort” strategies (damping, force increase closed to the rack end stops, etc.) must be
deactivated and a unique tuning file that uses full power of the EPS motor must be used.
 It is possible to propose a test only on motor. In this case, hand-wheel torque requirements
will be detailed into minimum motor torque in the reports.
Measur Steering Resistant Rack

ement Temp. wheel rack effort displacement
(°C) Fc Fm
No. speed [rps] [daN] [mm]
[daN] [daN]
1 1 to 3 0
Rack end-stop
2 1 to 2.5 0,9 * Fc
[-5 ;90] to rack end- See §5
3 0,5 to 1,5 0.9 * Fm
stop
4 0.1 to 1 Fm
 For each measurement point specified bellow, the supplier shall measure the current drawn by the EPS
 For 72°/s, 480°/s (360°/s à 10,5V) et 720°/s points, a matrix shall be done by the supplier.

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8V 10,5V 12,3V 16V 18V 24V
11,3V at 720°/s
TminHF N/A Characterization for If Test sheet 20 N/A N/A N/A
information only done, check the
EPS under phase A.
Or else : Nominal
EPS behavior, com
CAN, no DTC
raising
TminEF Nominal EPS N/A Nominal EPS Nominal EPS Nominal EPS N/A
behavior, com CAN, behavior, com CAN, behavior, com behavior, com
no DTC raising. no DTC raising. CAN, no DTC CAN, no DTC
Residual Requirement to fulfill raising. raising.
performance to Requirement to Requirement to
measure fulfill fulfill
-5°C N/A ((requirement N/A Nominal EPS N/A N/A N/A
above fulfill) behavior, com CAN,
no DTC raising.
Requirement to fulfill
25°C N/A ((requirement Nominal EPS Nominal EPS N/A N/A N/A
above fulfill) behavior, com CAN, behavior, com CAN,
no DTC raising. no DTC raising.
Requirement to fulfill Requirement to fulfill
Tmoy N/A (requirement Nominal EPS Nominal EPS N/A N/A Nominal EPS
above fulfill) behavior, com CAN, behavior, com CAN, behavior, com
no DTC raising. no DTC raising. CAN, no DTC
Requirement to fulfill Requirement to fulfill raising.
Residual
performance
to measure
TmaxEF Nominal EPS Nominal EPS Nominal EPS Nominal EPS Nominal EPS N/A
behavior, com CAN, behavior, com CAN, behavior, com CAN, behavior, com behavior, com
no DTC raising. no DTC raising. no DTC raising. CAN, no DTC CAN, no DTC
Residual Requirement to fulfill Requirement to fulfill raising. raising.
performance to Requirement to Requirement to
measure fulfill fulfill
TARGET
 cEPS performances must comply with the templates in paragraph 5.2.5 “assistance performances related
to temperature and power supply voltage”
 The pinion torque (Cc (N.m)) has to be plotted with respect to the steering wheel speed ( in rps) for the
output force value (Fsi (daN))
 Check that the sizing requirements are fulfilled (see §5.2.5)
 After endurance test (Sheet no. 20)

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 It is necessary to keep the torque [Nm] and speed [rps] values at the slope change (see red circles below)
Torque
and, [Nm]
if necessary, to overlay these values to assess the EPS performance.
Speed [tr/s]

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N°05: ASSIST PERFORMANCE RELATED TO THE RACK TRAVEL
OBJECTIVE
Validate the system performances related to the rack travel.
TEST PARTS
Electrical power supply system
ASSEMBLY
The mechanism shall be tightened at the nominal torque on a rigid fixture by its fastening.
The mechanism is associated to a constant force generator device (see requirement).
LOADS
The assistance is activated. The steering wheel shall be rotated until the rack end stopson the right and on the
left). Two measurements have to be performed, one at a steering wheel speed of 0.2 rps and the other at 1 rps.
The file [A1114] provides the rack force related to time and the steering wheel angle.
 assistance activated, the aim of this test is to check the system performances :
 “comfort” strategies (damping, force increase closed to the rack end stops, etc.) must be
deactivated and a unique tuning file that uses full power of the EPS motor must be used.
 It is possible to propose a test only on motor. In this case, hand-wheel torque requirements
will be detailed into minimum motor torque in the reports.

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N°06: THERMAL PROTECTION PERFORMANCES
OBJECTIVE
Validate the system performances in case of intensive use.
TEST PARTS
ASSEMBLY
The mechanism shall be tightened at nominal torque by its fastenings on a rigid fixture.
The mechanism is associated to a force generator (could be configure related to time) device.
LOADS
Definition of a « parking maneuver ».
Rack force data and angle with respect to time are provided in file [A1112],
Vehicle speed = 0 km/h
2000 800
1500 600
steering wheel angle (deg)

1000 400
rack force (daN)
500 200
0 0
0 2 4 6 8 10 12 14 16
-500 -200
-1000 -400
-1500 -600
-2000 -800
time (s)
Example of profile (not representative)
With:
Steering stop_angle [degrees] = ½ rack travel [mm] / ratio [mm/tr] * 360
RACK END HOLDING TEST
- Vehicle speed V= 0 km/h.

- Soak the mechanism at a temperature Tmoy
- Measure the variation of engine and controller skin temperatures as well as the current related to time.
- Rack displacement is locked.
- A 10Nm torque is applied on the steering wheel for 60 seconds.
- After the maximum lock holding period, a parking maneuver is performed (see doc)

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- Temperature and current measurements shall be carried on for 60 minutes after the maneuver.
ENDURANCE LOAD TEST
- Vehicle speed V= 0 km/h.

- Soak the mechanism at a temperature Tmoy
- The EPS is submitted to the following cycle:
3 fois
10 Manœuvres élémentaires
20 mn de pause
10 fois
2 mn de pause
20 mn de pause
An elementary maneuver is defined by:

Action Duration (s)
Start 0
Straight line position 3
Right steering 1,5
Right rack end stop 2
Return to middle point 1,5
Left steering 1,5
Left rack end stop 2
Straight line position 6,5
Right steering 1,5
Right rack end stop 6
Left steering 1,5
Left rack end stop 6

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Right steering 1,5
Straight line position 3,5
Left steering 1,5
Total 60
Force and angle data with respect to time are provided in file [A1113].
LOAD TEST DURING A « PTR2 THERMAL PEAK » CYCLE

After soaking the mechanism 30 minutes at ambient temperature Tmoy+10, the EPS is submitted to ambient
temperature cycle (« PTR2 thermal peak»). During this cycle, at t=34s seconds, the EPS is submitted to two «
parking maneuvers » cycles (as defined below):
«Heat increase PTR2» cycle

Time (s) Steering T° (°C)
0 Tmoy+10
34 Tmax_EF
56 Tmax_EF
67 TmaxEF
112 TmaxEF
123 Tmoy+16
190 Tmoy+16
246 Tmoy+10
TARGET
Measured graphs shall be integrated into test report.

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N°07: MECHANICAL FRICTION
OBJECTIVE
To check the sliding force level
TEST PARTS
Rack effort generator
ASSEMBLY
The mechanism is fixed with its sealing boots on a rigid fixture by its fastenings.
A dynamometer, a speed and travel servo control is mounted at the end of one tie rods.
A displacement sensor is also fixed in parallel with servo control device.
STRESS
The system is not powered up.
It is positioned at the rack end stop.
The rack is moved by the servocontrol actuator along its axis at a speed of 1m/mn.
The cycle consists of a forward and a backward movement.
The force is recorded related to rack displacement at 500Hz frequency.
TARGET
As a reference, the measurement is taken with the sealing boots (control configuration on finished product). If the
measurement is taken without boots (supplier plant configuration), 13N must be subtracted from the requirements.
Given (
Fd i )1≤i≤n the forces measured on a bench while turning right and ( Fg j ) 1≤ j≤m the forces measured on a
bench while turning left
Average friction:
 The average friction is the mean of the effort in a band of +/-30mm around the centre point without filtered
data:
n m
|∑ Fd i| |∑ Fg j|
Fd ave= i=1
Fgave = j=1
n ; m
Fd ave + Fgave
F ave=
2

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Fgave
Fdave
Force variation:
 Force variation is the measurement of the difference between the min and the max of the forces in an area
of +/- 30mm around the middle position after data have been filtered and in each direction:
o Filter: elliptic low-pass
o Cutoff frequency: 0.551 Hz
Fgmax
Fgmin
Fdmin
Fdmax
Measured curves have to be integrated in the test report.

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N°08: WEIGHT
OBJECTIVE
To comply with the requirement of the steering system.
TEST PARTS
Whole steering system with fasteners, functional assistance module, tie-rods and harness.
ASSEMBLY
The parts are put down on the plate of a balance.
LOAD
Each individual component is weighted separately.

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N°09: GEAR RATIO REDUCTION
OBJECTIVE
Check that the mechanism gear reduction is appropriate.
TEST PARTS
Rotational actuator
Rack travel sensor
Column angle sensor
ASSEMBLY
The mechanism is tightened on a rigid fixture by its fastening.
The servo control is fixed to the input shaft.
LOADS
Starting from the center position , the input shaft is turning by “ 360° +/- 1°” at the speed of 90°/s +/-1°/s in counter
clockwise followed by clock wise.
Rack travel related to the input shaft angle is monitored and recorded

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N°10: TIE ROD TILTING AND ROTATIONAL TORQUE
OBJECTIVE
Ensure that the tilting and rotational torques of ball joints (inner and outer tie rod) are appropriate.
TEST PARTS
Inner tie rod
Outer tie rod.
ASSEMBLY
The inner tie rod is mounted on the rack and the rod is free.
The outer tie rod is fastened on the knuckle fitted on a rigid fixture.
ASSEMBLY DIAGRAM
Diagram given for information only
LOADS
The following measurements are taken after the removal of the protecting elements.
Be careful that the inner or outer tie rod ball joints have not been moved before the test.
The displacements must be performed at 10 rpm speed for the rotation and 2 rpm for the tilting.
To be measured:
- The maximum breakaway torque before tilting CDB, from the initial position of the Rod knuckle regarding the
ball joints position.
- The maximum breakaway torque before tilting in an area α that equals the half tilting angle defined on the
drawing, this area being substantially centered on the outer ball joint axis and in the plane of the outer ball joint
axis and the rod.
- The maximum breakaway torque before rotation.
- The maximum rotational torque during a complete revolution in every angular position of the ball joint defined on
the functional drawing [A4010].

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N°11: ACOUSTIC LEVEL
OBJECTIVE
Ensure that the steering system is not audible by passengers inside the vehicle and people located outside.
TEST PARTS
Silent Rack force generator (rubber feet)
Silent Rotational actuator
ASSEMBLY
The mechanism is tightened on a rigid fixture by its fastening elements at the nominal torque.
The mechanism is loaded by a system (at the tie rods level) reproducing the parking forces (file [A1111]).
ASSEMBLY DIAGRAM
Vehicle speed and

Force sensor engine speed
Torque sensor Stabilized

power supply
ECU
LOADS
The test is performed for different steering wheel speed values:
 Perform a static acquisition
 Perform several acquisitions at constant speed: from 72 °/s to 720 °/s without impact on the Rack end
stops.
 Perform an acquisition at 360°/s with and without impact of the Rack end stops.
If there is a force increase strategy closed to the rack end stop, perform one acquisition with the function disabled
and another one with the function activated.
RADIATED NOISE TEST
The radiated noise is measured in a semi-anechoic chamber, for the five microphone points, distributed on the
three vehicle axes X, Y and Z at 1 meter from the mechanism’s central point (see illustration below).
The mechanism is loaded by a system (at the tie rods level) reproducing the parking forces.
The test is performed for different steering speeds: first test in static and then with a constant speed without impact
on the rack end stops : 90°/s, 180°/s, 360°/s, 540°/s, 720°/s.
Additionally, perform an acquisition at 360°/s without and with an impact on the rack end stop (If there is a force
increase strategy closed to the rack end stop, perform one acquisition with the function disabled and one other with
the function activated).
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The mechanism is tightened on a rigid fixture (see diagram below). EPS noise is recorded during a complete
maneuver (stop to stop). It is then recommended to perform an average spectrum for each microphone.
The 1/3 octave spectrum in dB(A) and narrow bands for the noisiest part (the strongest signal from the 5
microphone) is represented in dB(A) in the [100-10000]Hz. The window used is “Hanning” and the spectral
resolution is 4 Hz.
Z
90°
1m 1m Y
90°
BLOCKING FORCE TEST

The EPS is equipped with tri-axial load cells at the interfaces of its fastening points (see illustration below). This
configuration is valid for both rigid and filtered fastenings. The mechanism is loaded by a system (at the tie rods
level) reproducing the parking forces.
The test is performed for different steering speeds: first in static condition and then with constant speed without
rack end stop impact : 90°/s, 180°/s, 360°/s, 540°/s, 720°/s.
EPS blocking forces are recorded during a stop to stop maneuver (without rack end stop impact). It is then
recommended to perform an average spectrum (RMS average value) for each recorded channel.
The curves are plotted in the narrow band and in RMS over the [100-4000] Hz range with a resolution of 2Hz,
“Hanning” window and overlap of 90%.
Loading system
1 2
Measurement cells
BLOCKING FORCE TEST OF THE EPS SYSTEM WITH « BACKLASH » TYPE EXCITATION AND LOCKING FORCES OF THE EPS
SYSTEM AT END STOP
The EPS is equipped with tri-axial load cells at the interfaces of its fastening points (see illustration below). This
configuration is valid for both rigid and filtered fastenings. The mechanism is loaded by a system (at the tie rods
level) reproducing the parking forces.
The curves are plotted in the narrow band and in RMS over the [100-4000] Hz range with a resolution of 2Hz,
“Hanning” window and overlap of 90%.
Measurements are performed with backlash excitation type: angular oscillation at a frequency of 5Hz in +/-10° sine
wave. Acquisition duration: 20 sec. (RMS average value).
Additional measurements are required for rack end stop impact at 90°/s, 180°/s, 360°/s, 540°/s and 720°/s.

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N°12: ASSEMBLY EFFORT
OBJECTIVE
To check the steering ball joint assembly on the knuckles
TEST PARTS
Steering ball joint with its possible protections.
Wheel knuckle.
A tool for the measurement of the applied force on the ball joint.
ASSEMBLY
The wheel knuckle has to be fixed in order to stay motionless during the ball joint installation.
The effort shall be applied on the ball joint ensuring to keep enough degrees of freedom to avoid any arcing
phenomenon.
ASSEMBLY DIAGRAM
Diagram for information only
Wheel knuckle
STRESS
An effort in the ball joint axis shall be applied.
OBSERVED DATA
The value of this force allowing a thread length of X mm (see requirement) shall be recorded.

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N°13: BREAK-AWAY FORCE
OBJECTIVE
To measure the break-away force
TEST PARTS
Power supply
Vehicle signal generator (vehicle speed, engine state, IGN, etc….)
ASSEMBLY
The mechanism shall be tightened at nominal torque by its fastenings on a rigid fixture.
The mechanism is associated to a force generator device able to apply a load gradually and smoothly on the rack
end. To minimize the friction created by the assembly it is recommended to use a pulley with ball bearings.
A displacement sensor (ideally without contact) allows measuring the rack bar displacement related to time.
A load sensor (balance) allows measuring the tank mass related to time.
The acquisition has to be performed on the same time base (time synchronization).
ASSEMBLY DIAGRAM
Diagram only for information
LOADS
 In case of the proposed assembly, a cistern weight shall be gradually increased (using a liquid or sand, for
example) creating an axial force on the rack through a pulley.
 The cistern fill-up shall be stopped when a movement is observed
 2 tests shall be performed:
o 1. Power-Off
o 2. Assistance-ON (IGN = ON, Vvhl = 0 Km/h, Engine state = RUNNING)
OBSERVED DATA
 The cistern weight shall be measured before the test (to accelerate the test, the cistern can be weighted) =
Weight_cuve (t0)
 The tank weight should be measured before the test = Tank_weight (t0)

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N°14: GRII NOISE TEST
OBJECTIVE
To evaluate the system EPS regarding the Grii Noise
TEST PARTS
Short gear with
ASSEMBLY
The mechanism shall be tightened at nominal torque by its fastenings on the Z axis table of the vibration device.
A weight of 400g is added at the end of inner tie rod to represent the complete weight of the tie rod.
A weight of 1200g is also added at the end of the upper shaft to simulate the weight of the column.
An accelerometer is added on the upper shaft weight.
ASSEMBLY DIAGRAM
Diagram only for information
A proposed geometry for the weight is available in file [A4030].
LOADS
The actuator is controlled on Z axis with the following pattern:
Frequency 10Hz 20Hz 30Hz 200Hz 1000Hz
ɣ en 0.001 0.1 0,5 0,5 0,001

(m/s²)²/Hz
OBSERVED DATA
 The Y vehicle direction acceleration value (peak value) of the upper shaft is recorded and plotted on the [0-
4000]hz frequency spectrum, sampling method of 8khz, resolution of 1 hz, “hanning” window, overlap 75%
and average of 250 .

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N°20: MIXED DURABILITY TEST (MECHANICAL RESISTANCE)
OBJECTIVE
Validate the mechanical resistance of the steering system.
TEST PARTS
Steering system (including harness and tie rods)
Electric power supply system
Rotating actuator
ASSEMBLY
The mechanism is fixed on a rigid fixture by its fastening.
The mechanism is positioned according with the car coordinates (reference position).
Tie rod must be set to their maximum lengths (minimum number of engaged threads).
The tightening torque of the different assemblies must respect at least the official tolerance interval.
ASSEMBLY DIAGRAM
Enceinte thermique Thermal enclosure

Moto reducteur Moto reduction
Capteur de couple Torque sensor
Simulation vitesse véhicule et régime moteur Vehicle speed and engine speed simulation
Alimentation stabilisée Stabilized supply
Calculateur Controller
Pivot Knuckle
STRESS
ENDURANCE

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01452_13_00009 BMPV / 1V5 101/178
Reference scenarii
Effort [daN] 1V5-1 1V5-2 1V5-3 / B-MPV
Fp1 310 334 363
Fv 124 133 184
Fa 62 67 92
Fp2 325 350 375
Options
Effort [daN] 1V5-0 B-MPV A B-MPV B B-MPV A+B
Fp1 286 377 372 384
Fv 114 186 186 186
Fa 57 93 93 93
Fp2 300 394 388 401
Hot spots are created during C and D type sequences.

These hot spots last for 2 hours and are created in sequences of 5 minutes with intervals of 1h30.
Their temperature is TmaxEF and they are created on:
 The middle of the sealing boot.
 The location where the sealing boot is attached to the housing
 Yoke or eccentric Rack bushing
 The assistance motor
Effort of curb push away by the front of the wheel MPD (curb push away No.1)
Effort of curb push away by the back of the wheel MPD (curb push away No.2):
Effort of curb push away by the front of the wheel at the durability mass (curb push away No.3):
Effort of curb push away by the wheel back at the endurance mass (curb push away No.4):
Reference scenarii
1V5-1 1V5-2
N°1 N°2 N°3 N°4 N°1 N°2 N°3 N°4
EOT 1505 -1290 1453 -1245 1589 -1362 1537 -1317
Tie rod 1
Center 502 -430 484 -415 530 -454 512 -439
EOT -151 129 -145 125 -159 136 -154 132
Tie rod 2
Center -151 129 -145 125 -159 136 -154 132
1V5-3 B-MPV
N°1 N°2 N°3 N°4 N°1 N°2 N°3 N°4
EOT 1675 -1436 1622 -1392 1680 -1440 1628 -1395
Tie rod 1
Center 558 -479 540 -464 560 -480 543 -465
EOT -168 144 -162 139 -168 144 -163 140
Tie rod 2
Center -168 144 -162 139 -168 144 -163 140

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B-MPV A
N°1 N°2 N°3 N°4
EOT 1680 -1506 1628 -1449
Tie rod 1
Center 560 -502 543 -486
EOT -168 151 -163 146
Tie rod 2
Center -168 151 -163 146
Options
1V5-0
N°1 N°2 N°3 N°4
EOT 1421 -1218 1369 -1173
Tie rod 1
Center 474 -406 456 -391
EOT -142 122 -105 117
Tie rod 2
Center -142 122 -105 117
Note:
 Sign agreement:
o Positive for traction
o Negative for compression
WEAR- IN
The wear-in is defined by a succession (10 times in a row) of the following sequence:
2 parking cycles
+
8 cornering cycles
+
35 motorway cycles
MISCELLANEOUS
The rod elasticity will be measured after test according to the protocol of test sheet N°33 «Tie rod fatigue».
A part will be transmitted to PSA after endurance test for analysis.

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N° 21: CRD DURABILITY (ACOUSTIC BEHAVIOR)

OBJECTIVE
To validate the wear level of the steering system and its acoustic behavior.
TEST PARTS
Electrical supply system
Vehicle signal generator (vehicle speed, internal combustion engine state, IGN, etc.)
Rotational actuator
ASSEMBLY
The mechanism is fixed on a rigid fixture by its fastening.
The mechanism is positioned in respect of the in car coordinate (reference position).
Tie rod must be set to their maximum lengths (minimum number of engaged threads).
The tightening torque of the different assemblies must respect at least the official tolerance interval.
ASSEMBLY DIAGRAM

01452_13_00009 BMPV/1V5 104/178
LOADS
The profile is issued from 6 single data file distributed as defined below:
 Curb push away « DT » x 30
 Small Circuit « PT » x 1520
 Middle Circuit « MC » x 3200
 Parking maneuver « MP » x 25000
 Adherence Triangle « TR » x 380
 Pothole « NdP25 » x 380
These cycles represent 100% of the endurance test that must be performed.
These road profiles must be associated with the following thermal profile:
Ambient
% of test
temperature to apply
0% Subjective in-car evaluation and storage at -40° during 8h

Manœuvre Parking x 1055
Triangle d'adhérence x 16
Nid de Poule x 16
25°C Séquence A
Dégagement Trottoir x1
Petit Circuit x 64
Moyen Circuit x 135
Nid de Poule x 48
0% - 20% 80°C Séquence B
Petit Circuit x 191
Moyen Circuit x 402
Nid de Poule x 12
100°C Séquence C
Petit Circuit x 49
Moyen Circuit x 103
20% Evaluation acoustique puis stockage DAE à -40°C pendant 8h
25°C Séquence A
80°C + Séquence B
100°C + Séquence C
20% - 60%
-30°C Séquence A
80°C + Séquence B
60% Evaluation acoustique puis stockage DAE à -40°C pendant 8h
25°C Séquence A
80°C + Séquence B
60% - 100%
-30°C Séquence A
80°C + Séquence B
100% Evaluation acoustique
Table 9: Endurance thermal profile

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For the 30 curb push away they are divided into 4 parts as described in test sheet 20
Parking maneuver is defined in the specific file [A1112].
The data issued from the vehicle specific recordings (Middle circuit, small circuit, adherence triangle, pothole) and
the thermal profile are provided in document «xxx EPS CRD profile» [A1082].
Temperatures (ambient) must be applied on the following parts (at least):

- Reducer gear wheel
- Rack pinion clearance adjustment mechanism
- Rack bearing or Yoke
- Ball joints seat of tie rods
Notes:
 The sign agreement used is:
o Positive for traction
o Negative for compression
TARGET
The EPS must not have any fractured teeth, seizing, abnormal play or damage to the sealing boots.
The average friction load « average F » after test must comply with the requirement of test sheet N°07
After the endurance test, the mechanism must meet the requirements in sheet N°01 (assist law measurement) and
sheet N°03. (performances related to steering wheel speed).
MISCELLANEOUS
The rod elasticity will be measured after test according to the protocol of test sheet N°33 «Tie rod fatigue».
A part will be transmitted to PSA after endurance test for analysis.

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N°22: RESISTANCE TO VIBRATIONS
OBJECTIVE
Check and ensure the EPS resistance to vehicle vibration constraints.
TEST PARTS
Power supply
ASSEMBLY
The mechanism has to be fixed by its fasteners on a support which is submitted to the accelerations described
below. The EPS fastener has to be representative of the fastener on vehicle.
During the test, the EPS shall be supplied with assistance activated Mdf3.2 (refer to HW specification). The supplier
shall propose a way to move the rack during the test.
The system shall be fixed in its vehicle position.
STRESS
METHODOLOGY
The test shall be performed based on the two following phases:
 A natural frequency search (§5.6.4.15.4.2),
 A DSP excitation (§5.6.4.15.4.3).
The DSP excitation enables to check the EPS ageing when it is submitted to a durability test.
SEARCH AND STUDY OF RESONANCE FREQUENCIES (OR CRITICAL FREQUENCIES)

The search shall be performed in the following way:
The sensor weight has to be at least 20 times lower than the EPS weight. The search and study of natural
frequencies have to be performed at min temperature (TminEF) and at max temperature (TmaxHF) by making a
sweep (forward-backward) in the frequency range [0-200 Hz]. A natural frequency is expressed by an overvoltage
at an indicated frequency. The natural frequency search means to know the sufficiently significant overvoltage. A
natural frequency is taken into account when, at an indicated frequency, a magnitude higher than 3dB is observed
as below:
Valeur Value
amesurée ameasured
aconsigne asetpoint
3dB represents a √ 2 variation (20 log √ 2 = 3 dB)

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With ameasured and asetpoint defined as below:
amesurée ameasured
aconsigne asetpoint
consigne setpoint
mesure measurement
RANDOM VIBRATIONS
The EPS shall be submitted to random vibrations on each of the 3 main axes for a duration of 32 hours per axis.
A new EPS should be mounted on the vibration device. To ensure that its vibration behavior is identical, check that
its natural frequencies are equivalent by performing a simple sweep of the sinewave profile indicated in the
previous paragraph. The acceleration values indicated shall be applied along the vehicle axis.
DSP Norme 32h ((m/s²)²/Hz)

Fréquences (Hz) X Y Z
5 0,042 0,042 0,168
10 2,102 2,102 8,409
250 0,210 0,210 0,841
1000 0,001 0,001 0,004
2000 0,001 0,001 0,004
Table 4. DSP value depending on the frequency
DSP Norme DSP Standard
Fréquences Frequencies
The EPS is power supplied but not operating during the test (in order to reproduce its self heating).
MISCELLANEOUS
Each test has to be performed in 2 separate phases:
 1st test with all fasteners (internal and external to the mechanism) tightened at minimal torque
 2nd test with all fasteners tightened at maximal torque

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N°30: FASTENING TABS DURABILITY ON SUBFRAME
OBJECTIVE
Check the resistance to fatigue of EPS fastening tabs and the assembly on the subframe.
TEST PARTS
Rack housing.Studs and nuts.
ASSEMBLY
The rack housing is fixed on the rigid fixture by its vehicle fastenings. A threaded rod passes trough the housing
and is held by 2 spacers and tightened on the housing side. One of the rod ends is connected to a test actuator.
LOADS
Phase 1: 1 cycle at a frequency of 0.25 Hz in square pulse signal with an effort of:
BMPV Ref -1 584 daN 1848 daN

BMPV A -1657 daN 1848 daN
BMPV B -1584 daN 1848 daN
BMPV A+B -1657 daN 1848 daN
1V5-3 -1580 daN 1843 daN
1V5-2 -1498 daN 1747 daN
1V5-1 -1419 daN 1656 daN
1V5-0 -1339 daN 1563 daN
Phase 2: 25 000 cycles at a frequency of 1 Hz in square pulse signal. The applied effort on brackets and along the
casing main axle has to be :
BMPV Ref ± 744 daN

BMPV A ± 744 daN
BMPV B ± 744 daN
BMPV A+B ± 744 daN
1V5-3 ± 742 daN
1V5-2 ± 702 daN
1V5-1 ± 664 daN
1V5-0 ± 626 daN
Phase 3: 60 cycles at a frequency of 0.25 Hz in square pulse signal with an effort of:
BMPV Ref -1535 daN 1791 daN

BMPV A -1605 daN 1791 daN
BMPV B -1535 daN 1791 daN
BMPV A+B -1605 daN 1791 daN
1V5-3 -1531 daN 1784 daN
1V5-2 -1449 daN 1691 daN
1V5-1 -1370 daN 1598 daN
1V5-0 -1290 daN 1506 daN
The assembly tightening torque between casing and subframe has a minimal tolerance.
 The re-tightening torque on reference mark shall be measured after every phase.

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N°33: TIE ROD FATIGUE
OBJECTIVE
Check the resistance to fatigue of the tie rods.
TEST PARTS
Tie rod.
Wheel knuckle. The knuckle can be replaced by a rigid support
ASSEMBLY
One side of the tie rod is fixed to the knuckle (or rigid support) and the rack side is connected to an actuator and
tightened to the torque recommended by the supplier. The knuckle is fixed on a rigid plate. The number of threads
engaged between the inner and the outer tie rod is at the minimum tolerance level. The tightening torque of the nut
is at the minimum tolerance level.
ASSEMBLY DIAGRAM

01452_13_00009 BMPV / 1V5 110/178
LOADS
Force applied along the ball
Number Frequency Temperature joint axis
Phase Signal
of cycles [Hz] [°C]
Fmin (daN) Fmax (daN)
F1 Measurement under+/- 250 daN at 0,5 mm/min

F2 B-MPV, B 1 0.25 square 80 +/- 5 -1440 1680
F2 1V5-3 1 0.25 square 80 +/- 5 - 1436 1675
F2 1V5-2 1 0.25 square 80 +/- 5 -1362 1589
F2 1V5-1 1 0.25 square 80 +/- 5 -1290 1505
F2 B-MPV A, A+B 1 0.25 square 80 +/- 5 -1506 1680
F2 1V5-0 1 0.25 square 80 +/- 5 -1218 1421
F3 Measurement under +/- 250 daN at 0,5 mm/min
F4 B-MPV, B 25 000 0.1 square 80 +/- 5 +/- 372
F4 1V5-3 25 000 0.1 square 80 +/- 5 +/- 371
F4 1V5-2 25 000 0.1 square 80 +/- 5 +/- 351
F4 1V5-1 25 000 0.1 square 80 +/- 5 +/- 332
F4 B-MPV A, A+B 25 000 0.1 square 80 +/- 5 +/- 372
F4 1V5-0 25 000 0.1 square 80 +/- 5 +/- 313
F6 B-MPV, B 60 0.25 Square 80 +/- 5 -1395 1628
F6 1V5-3 60 0.25 square 80 +/- 5 -1392 1622
F6 1V5-2 60 0.25 Square 80 +/- 5 -1317 1537
F6 1V5-1 60 0.25 square 80 +/- 5 -1245 1453
F6 B-MPV A, A+B 60 0.25 Square 80 +/- 5 -1449 1628
F6 1V5-0 60 0.25 Square 80 +/- 5 -1173 1369
 The displacement is measured under +/- 250 daN and the tightening torque (mark tightening method) before
and after the test (« measurement »).

01452_13_00009 BMPV / 1V5 111/178
250
OBSERVED DATA
daN
MISCELLANEOUS
After the wheel shock on vehicle, PSA will provide a Tie rod to the supplier to complete the test above. The tie rod
have to comply to this test sheet after VC1 target.

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N°40: IMPACT TEST ON MECHANISM IN STEERING IN STRAIGHT LINE
OBJECTIVE
- Determination of the weak links
- Validation of the durability after successive impacts
TEST PARTS
Column
Steering wheel
ASSEMBLY
The EPS is fixed on a rigid fixture by its vehicle fastening in vertical position.
The tie rod is positioned with points N and M being vertical.
The mechanism is positioned in straight line.
The column that is fixed to the fixture horizontally is connected on the input shaft.
The steering wheel is assembled at the end shaft of column.
LOADS
- The mechanism is powered up.
- Simulate a vehicle speed of 5 km/h.
- A weight is dropped on one of the EPS tie rod end to reproduce impact energy of « Energy_Shock ».
- During the test, the steering wheel is held in position by the operator (without using the thumbs).
- The impact is repeated 10 times; after each time, the impacted tie rod is changed.
- After the 10th impact and change of tie rod, the EPS is submitted to a CRD Endurance Test and/or a Mix
endurance (Test sheet N°20 & N°21 & N°102).
Energy_Shock = bulking energy (see requirement BMPV/1V5_EPS_TS_SYSTEM_092 )
The test is performed on steering at right and steering at left applying the shocks on pinion side and on opposite
side.

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N°41: IMPACT TEST ON MECHANISM RACK END STOP POSITION
OBJECTIVE
Determine the weak links.
Determine the Energy level to create a failure (validation of the fastening tabs and end stops).
TEST PARTS
EPS with tie rods and with functional assist module
Rigid fixture
ASSEMBLY
The EPS is fixed on a rigid fixture by its vehicle fastenings in the vertical position.
The tightening torque between the mechanism and the fixture is at the min of its tolerance as determined on
functional drawing.
The mechanism is positioned at the rack end stop position.
LOADS
After reading the position of the top plate: h 0, a weight of 20 kg is dropped form this position.
The weight height at the first impact is 0,2 m.
Height h increases by 0,2 m after each impact without tie rod change.
 After each impact, the tightening torque (mark tightening method) is measured and the brackets areas are
visually inspected. The fastenings are tightened at the initial torque before the next impact.
 If the supplier does not have a 20-kg weight: the height and weight are determined to represent an energy
increment of 40J.
The test shall be performed until a failure occurs (others failures than tie rod buckling).
MISCELLANEOUS
A test on both sides (left and right) is required.

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N°43: RESISTANCE TO EXCEPTIONAL EFFORTS
OBJECTIVE
The system shall withstand exceptional effort during curb push away and also withstand impacts on obstacles
during driving. The objective is to validate the EPS mechanical resistance.
TEST PARTS
Rotational actuator.
ASSEMBLY
The EPS is fixed on a rigid fixture by its vehicle fastenings.
A spacer is positioned between the rack housing and the inner ball joint.
LOADS
The module is powered up in order to load the pinion / input shaft axle of the mechanism.
Simulate a vehicle speed of 0 Km/h
The torque is applied by the input shaft.
3 torque values are applied successively at 3 different rack positions:
 100 N.m
 150 N.m
 200 N.m

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N°50: ACCELERATED CORROSION
OBJECTIVE
To check the tightness of the steering system in a corrosive thermal atmosphere close to vehicles condition, in
particular at the interfaces level between the aluminum housing.
TEST PARTS
EPS (including harness)
Rigid fixture
A test chamber composed of:
Spraying chamber (49°C + 1.1/-1.7°C)
Sprayers
Heating device
Salt solution supplying device
Water humidifier
ASSEMBLY
The EPS is fixed on a rigid fixture by its vehicle fastenings inside the chamber.
The tie rods are fixed on false knuckles. The Tightening torques must be minimum of the tolerance (all the
fastenings of the EPS, screw at the housing interface, …..)
The EPS is positioned according to the vehicle coordinate (passenger compartment isolated).
LOADS
 A SWAAT cycle consists of:
o 30 min aspersion with the electrolyte
o 90 min at 98% relative humidity
 The test shall be performed at 49°C + 1.1/-1.7 °C (chamber temperature)
 Cycle duration: 2 hours
 Number of cycles: 375 cycles (i.e. 750 hours)
 Salt solution composition:
NaCl = 24,53g/L
MgCl2 = 5,2 g/L
Na2SO4 = 4,09 g/L
CaCl2 = 1,16 g/L
KCl = 0,695 g/L
NaHCO3 = 0,201 g/L
KBr = 0,101 g/L
H3BO3 = 0,027 g/L
SrCl2 = 0,025 g/L
NaF = 0,003 g/L
 Solution stabilized at a pH between 2,8 and 3 using CH3COOH
 Compressed air saturated with water and humidified using a humidifier containing osmosis water heated at
(57 +/- 1)°C and increased to a pressure of 1,2 +/-0,4 bar.
 Regarding the other parameters, please refer to the standard.
OBSERVED DATA
 Service
The EPS must operate normally after the test (test sheet N°01)
 Mechanical/electrical properties
o The EPS must be waterproof after the test:
 Overpressure to air leakage rate measurement test,

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 If the first check is NOK (leakage), either:
- Perform test N°70
- to detect the leakage,
- Or perform a thousand-bubble test.
o A rating 3 is not allowed.
Analysis procedure
Observations shall be made on the whole EPS, with a focus at the different interface level close to the electronics.
Casing of Test/FMEA/FTA/FA
Parts Picture before and after test
Recommended operation Tomography and X-ray
Requested for aluminum housing

Microcracking with separated flange
Determination of cutting area

Part opening
by FMEA or X ray results
Rating of electrolyte penetration Macrography, binocular Location of the failed areas
Cutting on risky areas
cutting area at interface level

and defect areas Micrographic cuttings
RATING DEFINITION
The rating which has to be applied during the micrographic observations is:
Rating Description Aluminum housing and separate flange

0 No penetration through interfaces
1 The penetration stays limited under the seal
Cotation 2 if the following criteria below are respected :
2 The electrolyte penetration inside the EEE
but without reaching drivers, elements, - Corrosion Area / Eletrolyte presence on aluminia
punch grid – no risk of short circuit. below 2 mm after the interface.
- Electrolyte never reachs the electronic card.
- Electrolyte reach no way of internal fixture (screw…)
Cotation 3 if one of the criteria below is reached :
3 The electrolyte is on or close to electric
components (electronic card, punch grid, - Corrosion area / electrolyte presence on aluminium
electronic components). The short circuit upper than 2 mm after the interface.
risk is major
- Electrolyte penetration of salt on the plastic /
aluminium interface
- Visible corrosion start point on the punch grid and
electronics component
- Corssing corrosion on header or breathing cap
- On the microcutting : the layer, caverneous corrosion

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phenomena, cracks initiated by the corrosion pitting
TEST SYNOTPIC
Essais CCA
OK NOK
SWAAT 750h Correction Design
Cotation 2 MAXI NOK OK
SWAAT 1000h
Cotation 1 MAXI
ANALYSIS PROCEDURE TO APPLY
Material analysis Reference

Analysis of new part (plastic + metal) CPBM_CMPM06_0087
Analysis after corrosion test CPBM_CMPM06_0088
Analysis after vibration test CPBM_CMPM06_0089
Analysis of plastic materials CPBM_CMPM06_2167
Detection / measurement analysis of cracking on plastic boxes CPBM_CMPM06_2169
Analysis of metallic materials CPBM_CMPM06_2168

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EXAMPLE OF MACRO OR MICROGRAPHY AFTER A SWAAT TEST: CASE RATED 3
Water tightness
loss at interfaces
on metallic
housings
Water tightness
loss at the
aluminum
housing / plastic
flange interfaces
level.

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Layered
corrosion on
interfaces:
Corrosion
propagation
along an
organized
structure
Crossing
corrosion: the
corrosion
phenomenon
«crosses»
material either
through
Layer corrosion
on housing:

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Aluminum
corrosion by the
metallographic
structure of
alloy.
The corrosion
spreads by
some phases of
aluminum alloy:
in this case,
corrosion along
the eutectic (Si)
and intermetallic
of the alloy
Aluminum
corrosion by the
alloy
metallographic
structure
Aluminum
corrosion by the
alloy
metallographic
structure with a
cavern in the
material
Aluminum
corrosion by the
alloy
metallographic
structure with a
crack initiated on
a corrosion
pitting

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N°51: RESISTANCE TO CHEMICAL AND ATMOSPHERIC AGENTS (B21 7130/CL25)
OBJECTIVE
To validate the resistance of the EPS to the aggressive fluids of the engine compartment.
TEST PARTS
Vehicle signal generator (vehicle speed, engine state, IGN, etc….).
Rigid fixture
ASSEMBLY
The mechanism is fixed on a rigid fixture inside the chamber by its vehicle fastenings.
The tie rods are fixed on false knuckles.
LOADS
The complete mechanism is submitted to aggressive fluids according to the following cycle (sprayed fluid quantity
and test temperature must be respected):
The fluid quantity is sprayed intermittently using a spraying device with a flow rate from 17 to 28 cm3/min sweeping
over a 20-cm distance on all accessible areas of the EPS.
Spray = Use a spray bottle (fluid somewhat atomized)
Sprinkle = Use a gravity fed device with a spout with holes (i.e. watering can)
The spraying duration of each fluid should be 1 hour.

The waiting time between two fluids should be minimum 2 hours.
For system test :

- The processus of fluid application is PROCESS C (§9.3) of D47 1924.
- Each fluid have in be applied in Tmoy.
- The list of applicable fluid is defined in the B71 6000 standard.
For harness :
- The processus of fluid application is PROCESS A (§9.1) of D47 1924.
- The list of applicable fluid is defined in the B71 6000 standard.
- The temperature to apply on fluids is :

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N°52: CORROSIVE THERMAL ATMOSPHERE
OBJECTIVE
To check the EPS tightness in a corrosive thermal atmosphere in vehicle configuration.
TEST PARTS
Rigid fixture
ASSEMBLY
The EPS is fixed on a rigid fixture inside the chamber by its vehicle fastenings.
The tie rods are fixed on a false knuckle.
The tightening torques must be at minimum of the tolerances.
The EPS is in position and configuration as in the vehicle (passenger compartment isolated).
LOADS
The EPS is submitted to static and dynamic cycles during pre-established sequences. These cycles consist of
phases in which a corrosion mixture is sprayed with temperature and hygrometry variation.
During the dynamic phases, the mechanism is displaced over its full travel. The displacement is transmitted by a tie
rod. The device has to be tunable in amplitude and frequency.
The test consists of 5 successive phases:

1st phase: “Resistance to low temperature ”
 Cycle duration: 8 hours
 Static cycle.
 Test temperature: TminEF.
 At the end of the cycle, return to an ambient temperature of 20°C and dwell for 2 hours before phase 2.
2nd phase: “Resistance to corrosive atmosphere ”
 Cycle duration: 2*24 hours consisting of:
o 8 hours consisting of 10-minute sprinkling periods followed by 20-minute periods without
sprinkling.
o 16 hours without spraying.
 Dynamic cycle:
o Travel: stop-to-stop
 Frequency: 150 at 200/hour
o Tie rod displacement: +/-50mm (vertical)
 Frequency: 5500/hour
o Test temperature: 40°C
o The corrosive mixture consists of water, salt and sand (see miscellaneous).
3rd phase: “Resistance to hot and humid atmosphere”
 Cycle duration: 6 hours consisting of:
o static cycle: 3 hours.
o dynamic cycle: 3 hours.
 Test temperature: Tmoy
 Hygrometry: 95%
4th phase: “Resistance to high temperature ”
 Cycle duration: 16 hours consisting of:
o static cycle: 8 hours.
o dynamic cycle: 8 hours.
 Test temperature: Tmoy+10
 Hygrometry: dry atmosphere.
5th phase: “Resistance to corrosive atmosphere ”
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 Same cycle as phase 2 except for test duration: 24 instead of 48 hours
Throughout the complete spraying duration, the corrosive mixture must be continuously agitated to ensure its
consistency.
Entire duration of the test: 104 hours
Mixture composition:
 The corrosive mixture used consists of water, salt and sand.
 The composition and quantities of the mixture are determined as follows for 20 liters of water.
o 600 g. salt
o Housing sand:
 101 g. sand calibrated at 0.4mm.
o River sand:
 72 g. sand calibrated at <0.12mm.
MISCELLANEOUS
Each test has to be performed in 2 separate phases:
 1st test with all fasteners (internal and external to the mechanism) tightened at the minimal torque.
 2nd test with all fasteners tightened at the maximal torque.

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N°53: FEEDBACK TO THE DRIVER
OBJECTIVE
Validate the EPS performance submitted to a stress in reverse direction, with the steering wheel locked.
TEST PARTS
ASSEMBLY
The EPS is tightened on a rigid fixture by its fastenings at nominal torque.
The EPS is associated to a force servo control
ASSEMBLY DIAGRAM
STRESS
- Various measurements are made at following vehicle speeds: Vvhl = 100 Km/h, 115 Km/h, 130 Km/h.
5.6.5.1.1.1 IN STRAIGHT LINE
- A sinusoidal force of +/- 50daN is applied to the rack.
- The frequency variation [1 Hz - 20 Hz]
- The gain and the transfer function phase are measured: H = Torque_steering wheel / rack force
5.6.5.1.1.2 DURING STEERING
- A sinusoidal force of 200 daN  50 daN is applied on the rack
- The frequency variation [1 Hz - 20 Hz]
- The gain and the transfer function phase are measured: H = Torque_steering wheel / rack force
TARGET
The transfer functions measured must be included in the templates provided inside PSA requirement.

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N°54: DYNAMIC PERFORMANCES 1
OBJECTIVE
Validate the EPS dynamic performances in the direct direction configuration (from steering wheel to wheels)
TEST PARTS
Rotational actuator
ASSEMBLY
The EPS is tightened on a rigid fixture by its fastenings at the nominal torque.
The EPS is associated to a device generating a resistant force equivalent to a stiffness (see assembly diagram).
ASSEMBLY DIAGRAM
Vehicle speed and

Actuator
engine mode
Angle and d’angle
Capteur speed
sensor
et de vitesse Torque sensor Stabilized
supply
ECU
Force
sensor
LOADS
 A vehicle speed of V = 120 km/h has to be simulated
 The equivalent stiffness on the tip of the rack has to be 997 000 N/m
 The pinion angle of the steering is stressed with a sine-wave amplitude of +/- 10°. The frequency is
changed from 0,01 Hz to 7 Hz.
OBSERVED DATA
 The response function should be plotted:
H = Column torque / Steering wheel angle

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N°55: DYNAMIC PERFORMANCES 2
OBJECTIVE
Validate the EPS dynamic performances in the direct direction configuration (from steering wheel to wheels)
TEST PARTS
Rack force generator.
ASSEMBLY
The EPS is associated to a device generating a resistant force equivalent to a stiffness (see assembly diagram).
ASSEMBLY DIAGRAM
Vehicle speed and

Actuator
engine mode
Angle and d’angle
Capteur speed
sensor
et de vitesse Torque sensor Stabilized
power supply
ECU
Force
sensor
LOADS
 Simulate a vehicle speed V = 120 km/h
 The equivalent stiffness at the rack end must be 997 000 N/m
 The EPS is submitted to an angle input at constant frequency of 1Hz. The magnitude will be
progressively increased from 0 to 30°:

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OBSERVED DATA
 The graph Steering wheel torque = f(steering wheel angle) shall be plotted

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N°56: CENTERING AND STEERING WHEEL RETURN
OBJECTIVE
Check that the EPS comply with PSA requirements regarding Centering and steering wheel return.
Check that the friction efforts are compatible with a good centering and steering wheel return .
TEST PARTS
Torque and angle sensor
Rack force sensor
ASSEMBLY
The EPS is associated to a device creating a variable effort related to the rack displacement.
ASSEMBLY DIAGRAM
Vehicle speed and

Actuator
engine mode
Angle and d’angle
Capteur speed
sensor
et de vitesse Torque sensor Stabilised
power supply
ECU
Force
sensor
LOADS
CENTERING
 Simulate a vehicle speed of 120 Km/h
 The rack force generator is configured to simulate a spring function with a stiffness of 50 daN / mm.
 The input shaft is submitted to a variable angle magnitude (3° to 30°) on a cycle of 20s with a frequency of
1 hz (see curve below).

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STEERING WHEEL RETURN
 The rack force generator is configured to simulate a spring function with a stiffness of 7,5 daN / mm.
 The steering wheel is placed at an angle V
 Simulate a vehicle speed V
 The steering wheel is released :
Measurement no. Vehicle speed V Angle V (degree)of the steering
(Km/h) wheel when it is released
1 20 30°
2 20 90°
As a reference, a steering wheel with an inertia of 23 g.m² will be used.
OBSERVED DATA
CENTERING
 Plot the graph pinion_torque [Nm] = f(pinion_angle [degree])
 The hysteresis should shall be drawn on this curve:
o For the torque (Hc): this is the height of the curve when the angle = 0
o For the angle (Ha): this is the width of the curve when the torque = 0
Hc
Ha
STEERING WHEEL RETURN

 Measure the angle modification with respect to time.
 Record the steering wheel angle at 3s after the steering wheel has been released 3.
 Calculate the centering rate : (1- (3 / Vi ))*100

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N°57: STEERING STIFFNESS
OBJECTIVE
Check that the EPS complies with the requirements of steering stiffness (in both driver => knuckle and
knuckle=>driver direction)
TEST PARTS
Torque and wheel angle sensor
Rack force sensor
ASSEMBLY
ASSEMBLY DIAGRAM
Vehicle speed and

engine mode

supply
ECU
Force
sensor
LOADS
IN “KNUCKLES TO DRIVER” DIRECTION
 Input shaft is locked.
 The tie rod is submitted to a force of +/- 320 daN for a vehicle speed of 120 km/h, 0 km/h and with
assistance OFF
 This effort varies at a speed of about 20 daN/s (see curve below)

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400
300
200
Effort crémaillère [daN]

100
0
0 20 40 60 80 100 120 140 160 180 200
-100
-200
-300
-400
Temps [s]
IN “DRIVER TO KNUCKLES” DIRECTION

 Lock the tie rod by mounting it on a rigid false knuckle.
 Apply a triangular torque to the input shaft with an amplitude +/- 11 Nm for a vehicle speed of 80 km/h, 0
km/h with the assist OFF
 This torque varies at a speed of about 0,5 Nm/s
OBSERVED DATA
IN “KNUCKLES TO DRIVER” DIRECTION
 Plot the rack travel = f(rack force)
 The graph in assistance OFF situation has to be provided for information
IN “DRIVER TO KNUCKLES” DIRECTION

 Plot the pinion_angle = f(pinion_torque)
 Curves shall be provided to PSA.

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N°58: INITIALIZATION TIME FOR THE ASSISTANCE
OBJECTIVE
To check the delay before nominal assistance at initialization.
TEST PARTS
Torque and angle sensor
Rack force sensor
ASSEMBLY
The EPS is associated to a constant leveling force device.
ASSEMBLY DIAGRAM
Vehicle speed and

engine mode

supply
ECU
Force
sensor

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LOADS
 At the beginning of the test, no information shall be sent to the EPS and the power supply is cut off
(simulation of a vehicle in idle situation).
 The input shaft is locked
 A constant force of Fm is applied to the rack.
 Different situations have to be simulated :
 Case 1 : The starting conditions are initiated step by step:
o Electrical power supply system ON
o +IGN ON
o Transmission of engine state = DRIVING
 Case 2 : All the starting conditions are initiated at the same time (first engine state).
 Case 3 After case 1 or 2, cut off the IGN, and turn ON the +IGN in less than 1s
For the 2 first cases, do the test with and without the assist ramp
OBSERVED DATA
Plot the following curves:
 Electrical supply system = f(temps)
o Signal IGN = f (time)
o Engine state frame = f(time)
o Input shaft torque = f(time)
 Record t0 as the moment when the starting conditions are satisfied (power supply ON, IGN ON, 3 engine
frames = DRIVING received and valid)
 Record t1 as the moment when the input shaft torque is stabilized.
 t1-t0 shall be below the requirement BMPV/1V5_EPS_TS_SYSTEM_025

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N°59: ASSISTANCE LAW HYSTERESIS
OBJECTIVE
Understand the driver feeling during a parking maneuver.
TEST PARTS
Load sensor
ASSEMBLY
The rack is locked at the level of a tie rod.
ASSEMBLY DIAGRAM

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LOADS
 Simulate a vehicle speed of 0 Km/h
 From the middle point, sweep the torque (Cc) at 1,5  0,5 Nm/s.
o from 0 to –10 Nm (counter clockwise).
o then, from -10 to 10 Nm (clockwise).
o and from 10 to 0 Nm (counter clockwise).
Note: if necessary, the torque values can be increased to ensure that the entire torque sensor reading range is
used.
OBSERVED DATA
 Plot curve Fs = f (Cc)
o Fs: Rack force
o Cc: column torque
 The maximum hysteresis at Iso-force (see below) is given on the measured curve.
 Hysteresis values are given for information only
Force [daN]
Hysterisis in right
steering
Torque [Nm]
Hysterisis in left
steering

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N°60: INFORMATION FEEDBACK – DISPLACEMENT LOAD
OBJECTIVE
Validate the EPS performance during a stress in the reverse direction, with the steering wheel locked
TEST PARTS
Steering mechanism (harness included)
Electric power supply
Effort sensor
ASSEMBLY
The EPS is fixed on a rigid fixture by its fastenings at the nominal torque.
The EPS is associated to a force generator device that can be monitored according to time.
LOADS
- Simulate a vehicle speed V = 120 Km/h
- Perform an initial test by applying a rack displacement of +/- 0,1mm.
- Perform a second test by applying a rack displacement of +/- 0,2 mm
- For each test, the frequency varies from 0 to 30 Hz.
OBSERVED DATA
The gain and the transfer function phase are measured: H = Torque_steering wheel / Effort_rack

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N°61: OPERATION AFTER STORAGE (B21 7130/CL01)
OBJECTIVE
This test simulates the exposure of the EPS to temperatures encountered during transport and storage (before
assembly).
TEST PARTS
Steering system (harness included).
ASSEMBLY
The EPS is not connected but equipped with its complete harness.
Fix the EPS in climatic chamber (according to standard CEI 60068-2).
LOADS
The test consists of 2 successive phases:
- Exposure to low temperatures (24 hours)
- Exposure to high temperatures (48 hours)

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N°62: SELF-HEATING MEASUREMENT (B21 7130/CL06)
OBJECTIVE
To measure the self-heating of the EPS in order to determine the maximum temperature experienced by the EPS
(local temperature).
To determine the endurance test conditions under high temperatures.
TEST PARTS
Module EE with or without steering system
Supply harness with controller.
Electrical power supply system: voltage at the end of the EPS harness = Ua.
Vehicle signal simulator (vehicle speed, engine speed …)
Torque and position sensor
ASSEMBLY
It must be possible to position the electronic assembly in a climatic chamber with the possibility to measure the
component skin temperatures.
2 tests are required:

 At 23 5°C, cover open a measurement of the active component temperatures via IR camera
 At TMax EF, cover in position (in confined and stabilized environment) with thermocouples measurement of
the critical component temperatures determined during the test at 25°C via thermocouples.
The list of the critical components must be approved by PSA. At least: the power component, the
Microcontroller and the MOSFets, shunt, gate driver, capacitor, coil, relays, ICs...
ASSEMBLY DIAGRAM
To be specified in the test drawing
STRESS
The EPS or module is placed in the operating mode generating the maximum self heating for the
duration required for thermal stabilization.
The Torque is applied at the input shaft.
 The value of the torques and the possible load cycles must be selected in order to obtain the maximum
temperature of the components
 Several steering wheel torques or several load cycles may be necessary because the maximum
temperature obtained per component is not always the same and is dependent on the load profile.
The aim is the thermal protection of the steering system.

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N°63: AGEING BY AIR/AIR THERMAL SHOCKS (B21 7130/CL07)
OBJECTIVE
This test simulates the temperature variations due to the environment (sunshine and engine) and the
switching on and off of the equipment itself if it dissipates energy.
The failure mode is the crack on materials caused by the accumulation of thermal mechanical stresses
(association of materials with different thermal dilatation coefficients).
Failures may result of :
Opening of circuits: Break of brazed joints, small junctions and bonding.
Variation in the characteristics of certain ceramic components (capacity and resistance).
This is a reliability test, the thermal variation being greater to that viewed on the vehicle.
TEST PARTS
Complete steering system with its harness.
ASSEMBLY
According to the standard CEI 60068-2-14 Na (specified duration of the transition - method with 2 test chambers).
 The transfers between TmaxHF and TminHF have to be done under t2 =30s
 After introduction of the EST in the test chamber, the temperature has to be in the recommended range in
a time < 0,1. t1
 Step duration: t1 = 1h considering the EPS thermal inertia.
 Cycles number: 500
ASSEMBLY DIAGRAM
To be specified in the supplier test drawing.
STRESS
The test must be performed on the system being not power supplied

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N°64: THERMAL CYCLES DURABILITY (B21 7130/CL08)
OBJECTIVE
Validate the EPS performances during the thermal variations from the temperature mission profile.
TEST PARTS
ASSEMBLY
The EPS is fixed on a rigid fixture by its fastenings.
The EPS is mounted in respect with the vehicle coordinate (reference position).
STRESS:
The EPS has to be submitted to the following temperature profile:
TminEF
TmaxEF
Thermal variations: 20°C/minute
Number of cycle: 700
A test is performed at the end of each exposure cycle to low temperatures (see target)
A continuous test is performed during the cycle of exposure to high temperatures (the operating point must be
selected to avoid derating).

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N°65: ENDURANCE TO ACTIVATIONS (B21 7130/CL09) AND TO STT VOLTAGE SUPPLY
SITUATIONS (IC12)
OBJECTIVE
 Determine the mechanical wear of the mobile elements and the damage of the contacts, if present.
 Assess the active component failures (microcontroller, transistors, etc.) due to temperature
variations, bonding breakages, etc.
 Check the EPS reliability to power supply switching.
 Check the component failure due to STT load profile
TEST PARTS
Complete EPS with harness
Programmable electrical power supply system.
Switching system (electromechanical or electronic relay)
Vehicle signal generator (vehicle speed, engine speed…)
ASSEMBLY
The EPS must be putted in a climatic chamber(TminEF/TmaxEF).
The programmable power supply must be able to deliver a simulated battery voltage with or without operational
alternator, i.e. at 14V or 12V.
The switching device must be able to simulate the presence of rebounds on the relay (5) at each openclosed
switch.
Relay
Closed state
200 µs 200 µs 200 µs 200 µs 200 µs
max max max max max
Opened state Time

1 2 3 4 5
STT LOAD PROFILE

The controlled power supply shall be able to generate the STT voltage profile as specified.
This specific STT voltage profile shall be applied simultaneously on the inputs +APC and +Bat at the ECU.
Number of activations to be taken into account: 540 000
V
Ua =14V
Ustop = Ua
10,5V Usto
tf1 = 100ms p
ta = TBD 9,5V
tf2 = 5ms
tb = 3s
tr1 = 45ms
tr2 = 100ms t
RI = 0,01 
tf ta tf tr tb tr
1 2 1 2

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SOLICITATIONS
The EPS shall perform: 25 000 activations at TminEF, 70 000 activations at Tmoy and 25 000 activations TmaxEF,
so 120 000 activations altogether. The specific activations for STT have also to be added
An activation sequence takes place as following:
V
14
U apc
tc tc tc tc
Profil de tension STT
V T(s)
14
U Batt
tc tc tc tc
12
MDF 3.2 MDF 2.1 MDF 1.2

Max assistance
t1 t2 t3
MDF 1.2 = equipment not power supplied (but connected)

MDF 2.1= +BATT ON (12V) and +IGN OFF
MDF 3.2= +BATT ON (14V) and +IGN ON and engine state =running
The durations t1, t2, t3, tb, tc shall be defined so as:

 the capacities at the input have enough time to be loaded and unloaded
 the whole test duration doesn’t exceed two months

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N°66: ENDURANCE TO HIGH TEMPERATURE (B21 7130/CL10)
OBJECTIVE
This test simulates the functional and environmental constraints to which the EPS is subjected for the period of use
of the vehicle
TEST PARTS
ASSEMBLY
The EPS is positioned in respect with the vehicle coordinate (reference position).
LOADS:
The EPS is submitted to a temperature of Tmax EF during 60 days.
A continuous load is applied during the complete test (the operating point has to be selected to avoid derating
activation).
Variation of the supply voltage during the test:

Un = 13,5+/-0.2V

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N°67: DETERMINATION OF OPERATING LIMITS AT A TEMPERATURE (B21 7130/CL11)
OBJECTIVE
This consists of a sturdiness test or aggravated test. The principle is the increase in the environmental constraint to
higher values than the specified values, and this up to operating or destructive limits.
The objective is to age/wear the equipment more rapidly and to be aware of certain failure modes.
TEST PARTS
ASSEMBLY
The EPS is positioned in respect with the vehicle coordinate (reference position).
STRESS
The test is divided in 2 phases:
- Exposure to low temperatures
The EPS is submitted to a temperature of TminEF, decreasing by stages of 10°C/15 minute
- Exposure to high temperatures
The EPS is submitted to a temperature of TmaxEF, increasing by increments of 10°C/15 minute
-
A load is applied at the end of each temperature increment to check the EPS operation.
The test is applied until EPS failure.

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N°68: PROTECTION OF THE ENVELOPS AGAINST SOLID BODIES (IP5X) (B21 7130/CL13A
CATEGORY 1)
OBJECTIVE
The aim of this test is to check the tightness (IP5X) of the EPS passenger compartment (the interface between the
under-hood and the compartment part is determined by the dash panel joint).
TEST PARTS
EPS.
Dust chamber.
ASSEMBLY
According to CEI 60529 standard.
ASSEMBLY DIAGRAM
To be defined in the test plan
LOADS
IP5X according to IEC 60 529.
To perform a static test, the EPS is connected but not powered.
If the supplier identifies a risk related to a relative displacement of the input shaft, the test must be dynamic with a
rotation of the input shaft.

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N°69: PROTECTION OF THE ENVELOPS AGAINST LIQUIDS PENERATION (IPX3)
(B21 7130/CL13B)
OBJECTIVE
This test is intended to check the EPS cabin part sealing (IPX3) (the interface between the underhood part and the
cabin part is defined by the dash panel seal).
TEST PARTS
EPS
Spraying device or shower head.
ASSEMBLY
According to standard IEC 60 529.
ASSEMBLY DIAGRAM
To be defined in the test plan.
LOADS
IPX3 according to CEI 60529.
Perform a static test, the EPS is connected but not powered.
If the supplier identifies a risk related to a relative displacement of the input shaft, the test must be dynamic with a
rotation of the input shaft.
TARGET
After disassembly, there must not be any trace of liquid inside the EPS.

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N°70: VACUUM IMMERSION (IP68) (B21 7130/CL14)
OBJECTIVE
The aim of this test is to check the liquid tightness (IPX8) of the EPS under hood compartment (the interface
between the under-hood and the compartment part is determined by the dash panel joint).
TEST PARTS
Tank
Vacuum system
ASSEMBLY
The EPS is immersed in water (including harness). Only the compartment part of the EPS stays in air.
The vacuum in the EPS is applied by the passenger compartment part.
During the test, the EPS is connected but not powered.
ASSEMBLY DIAGRAM
LOADS
IP68 according to IEC 60 529.
Vacuum to be applied: Pmax + 50 mBar
Vacuum Pmax is determined in Hardware technical specification [A003].
Immersion duration: 2 hours.
TARGET
After disassembly, there must not be any trace of liquid inside the mechanism.

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N°71: THERMAL SHOCKS WITH ICED WATER (B21 7130/CL15B)
OBJECTIVE
The aim of this test is to check the water tightness (IPX8) of the EPS under hood compartment (the interface
between the under-hood and the passenger compartment part is determined by the dash panel joint) during a
significant and fast thermal variation.
TEST PARTS
Immersion system
ASSEMBLY
For this test, the harness is cut at connection level (copper is visible).
ASSEMBLY DIAGRAM
LOADS
Cycle definition:
The EPS is brought to a temperature of TmaxEF for 1 hour, then immersed in icy water (0°C to +4°C), including
harness copper. Only the compartment part remains in the air. The EPS shall be placed in Mdf 3.1 (refer to HW
specification [A003]).
Immersion duration: 5 minutes.
Number of cycles: 20.

TARGET
After disassembly, no trace of liquid inside the mechanism or the connections.

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N°72: HIGH PRESSURE WASH (IPX9K) (B21 7130/CL16)
OBJECTIVE
The aim of this test is to check the water tightness of the EPS under hood compartment (the interface between the
under-hood and the compartment part is determined by the dash panel joint) while cleaning the engine
compartment with a high pressure cleaner.
TEST PARTS
ASSEMBLY
During the test, the EPS is connected but not powered.
ASSEMBLY DIAGRAM
To be defined in test plan
LOADS
Before the test, the EPS is brought to TmaxHF for 8 hours.
Method 1: DIN 40 050 or ISO/WD 20653 (IPX9K) :

The EPS is placed on a rotating table : 5 (± 1) rev/min.
Nozzle/EPS distance between 10 and 15 cm.
Nozzle : 0°, 30°, 60°and 90°.
30 s per position.
High pressure wash equipment providing the following settings:
Displayed pressure : 100 (± 5) bar.
 Flow rate : 15 (± 1) l/min.
Cone jet : angle of 35 (± 5)°.
Temperature : + 80 °C.
Method 2:
Wash with detergent for 5 seconds, nozzle held at 30 cm from the EPS,
Tilt the nozzle 45° from either side of the vertical line.
Rinse in the same conditions without detergent for 3 minutes.
Repeat the same test with the nozzle at 10 cm from the EPS.
High pressure wash equipment providing the following settings:
Displayed pressure : 80 (± 5) bar.
Output : 13 (± 1) l/min.
Cone jet : 60° angle.
Temperature : 70 °C.
Detergent of the «Fréval» Durel SH598 type to 3 % or similar (with a pH less than 10).
TARGET
After disassembly, no trace of liquid inside the EPS or the connections.

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N°75: BALL DROP (B21 7120/M3.1)
OBJECTIVE
The resistance to impact tests (dropping of a ball, a beam and free fall) are completed to simulate the working
conditions of the EPS before assembly on a vehicle (handling at the supplier, transport, handling in plant and/or
after sale...).
TEST PARTS
Complete EPS
ASSEMBLY
A steel ball with 25,4 mm(67 grams) falls from 700 mm onto the device. It must being guided vertically by a
tube with an internal diameter sufficiently dimensioned to avoid any slowing during the fall. .
ASSEMBLY DIAGRAM
LOADS
For this test, the EPS is not connected.
Impacts are performed on the most fragile point of the EPS:

 connections (and generally plastic parts)
 part angles and joints
 input shaft
 breathing dots
 torque sensor

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N°78: TEST ON INTERNAL CONNECTION ELEMENTS (B21 7120/M1.2)
OBJECTIVE
Validate the resistance of the EPS harness connection with the mechanism.
5.6.5.1.2 TEST PARTS
Complete EPS
5.6.5.1.3 ASSEMBLY
For this test, the EPS is not connected (MDF 1.1) and placed on a rigid fixture. The harness must not be attached
to the mechanism (except for connections). The stress will be directly and completely applied to the connector/EPS
link.
5.6.5.1.4 ASSEMBLY DIAGRAM
5.6.5.1.5 LOADS
The jaw of the tensile testing machine must move at a constant speed ranging between 25 and 50 mm/min until
100 N is reached. Traction is carried out along the axis of the conductive output devices (axial traction) and
perpendicular to the axis of the conductive output device (perpendicular traction).

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N°79: HARNESS VALIDATION (B25 1140)
Refer to the B25 1140 [A3064] standard for specific tests.
For fluid compatibility please refer to Test Sheet N°51.

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N°80: PLASTIC MATERIAL AGEING RELATED TO CLIMATIC CYCLE (D47 1309)
OBJECTIVE
Validate the plastic part reliability regarding the specified requirements.
TEST PARTS
The tests must be carried out independently on specific components unless their integration in the EPS is likely to
have an impact on the results. In this case, the tests will be carried out on parts that are integrated in their
environment.
A control sample must be previously analyzed according to procedure [A5010].
ASSEMBLY
According to the test that must be carried out (shocks, peak thermal resistance, continuous thermal resistance and
aging).
ASSEMBLY DIAGRAM
To be given on the test drawing
LOADS
1) Shock tests
Refer to standard D42 1235. 2 tests must be planned
- Mobile part of form B of 1000g that falls from 50cm at 23°C
- Mobile part of form A of 200g that falls from 50cm at -30°C
2) Peak thermal resistance

See standard D45 1234 24h à TmaxEF
3) Continuous thermal aging

See standard D45 1234 1000h at Tmoy
The shock tests at 23°C according to D42 1235
4) Aging during climatic cycle

See standard D47 1309
Carry out 10 cycles according to template BF (10 days of test)

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N°90: SWEPT SINE PARKING MANEUVER
OBJECTIVE
Validate the system response to a severe parking maneuver.
TEST PARTS
ASSEMBLY
The EPS shall be tightened on a rigid support by its fasteners at nominal torque.
The saturated spring at the end rack shall have the following stiffness :
BMPV 1V5
Fssc = F120° 430
Yssc 8
Stiffness(N/mm) 52
Saturation (N) 430
The EPS is power supplied. The voltage across terminals is specified in the requirement.
The test temperature is specified in the requirement.
ASSEMBLY DIAGRAM
LOADS
 The steering wheel angle is a sinewave signal swept in 120° amplitude frequency

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OBSERVED DATA
The signals which have to be analysed are:
 The steering wheel torque related to time
 The steering wheel speed related to time
 The effort at the rack end related to time.

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N°91: STEERING WHEEL TORQUE PEAK DURING AVOIDANCE MANEUVER
OBJECTIVE
Validate the response of the system to a dynamic stress (avoidance maneuver).
TEST PARTS
ASSEMBLY
The saturated spring at the end rack shall have the following stiffness:
Project BMPV 1V5

Stiffness(N/mm) 27
Saturation (N) 367
The EPS is power supplied. The voltage across terminals is specified in the requirement.
LOADS
The steering wheel angle profiles are available in the file ILDR_AFDH08_0686_Angle_Steering_Wheel (see doc
[A1115]).

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25
Cmax
20
15
Couple (N.m)
10
0,2 s
C0,2s
0
0 0,05 0,1 0,15 0,2 0,25 0,3 0,35 0,4
Temps (s)
NO.99: ELECTRIC
CONSUMPTION
OBJECTIVE
Estimate the current consumption of the EPS system.
TEST PARTS
ASSEMBLY
The EPS has to be linked to a system creating a constant effort (see below).
The EPS has to be power supplied.
STRESS
The tests have to be performed with the steering assistance activated, for voltages across the EPS terminals of
10.5, 11.3 and 14,5 V. The “comfort” strategies (damping, effort increasing close to the rack end stop, etc…)
have to be deactivated.
 The steering rack should be positioned:
o at rack end stop if the steering wheel speed is not null
o at mid-travel (on the right or on the left) if the steering wheel speed is null.
 The steering rack should be submitted to the specified effort and the steering wheel should be turning at
the specified speed.
 The steering wheel torque is also defined
Steering
Steering wheel Resistive rack effort Rack
Measurem wheel
torque [daN] displacement
ent No. speed
[N.m] [mm]
[rps]
BMPV 1V5
1 0 3 No
2 0.2 3
Load = (Fc+Fm)/2 From end stop
3 0.5 3
to end stop
4 1 3

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5 0 4 No
6 0.2 4 In-car collected datas at 50 km/h and 90°
From end stop
7 0.5 4 steering wheel angle
to end stop
8 1 4
9 0 5 No
In-car collected data at 90 Km/h and 45°
10 0.2 5 From end stop
steering wheel angle
11 0.5 5 to end stop
12 1 5

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N°100: PERFORMANCE OF CITYPARK ANGLE CONTROL
OBJECTIVE
Validate the EPS angle control performances of the CITYPARK function.
TEST PARTS
Complete steering mechanism with functional assistance module and CITYPARK angle control
module.
Power Supply voltage.
Signal generator simulating the vehicle speed and the engine condition.
Signal generator simulating the CITYPARK CAN communication.
ASSEMBLY
The mechanism has to be fixed on a rigid support by its fasteners at nominal torque
The column linked to the mechanism has to comply with the vehicle installation.
The mechanism has to be associated to a system creating a Fparking effort varying in function of the
rack position [A1115]
The steering wheel should be free. No torque should be applied to it.
Force sensor
Stabilised power
Vehicle speed and engine

speed simulation
ECU
Steering wheel
speed sensor+angle
sensor
Torque
sensor
Rack in rest
5.6.5.1.6

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SOLICITATION
A null vehicle speed (parking) has to be simulated V=0km/h.
The mechanism creating the effort should apply an effort depending on the rack position.
A CityPark function activation should be simulated during a CityPark parking maneuver.
Definition of the CityPark parking maneuver:

The parking maneuver corresponds to a stop to stop cycle starting from 0 and returning to the center.
To be realistic, the setpoint is developped from filtered step by a second order filter with wr=31rd/s,
ζ=0,7 and maximal steering wheel acceleration=1000°/s² and maximal steering wheel speed=450°/s.
A maximal position holding has to be done (90% of the travel) during 5s.
Manoeuvre parking CityPark
600
400
Consigne d angle volant CityPark
200
-200
-400
-600
0 2 4 6 8 10 12 14 16 18
Temps [s]
The CityPark steering wheel angle setpoint and the steering wheel angle measurement are plot
600
Consigne d angle CITYPARK
Mesure d angle volant
400
Consigne et mesure d angle volant CityPark
200
-200
-400
-600
0 2 4 6 8 10 12 14 16 18
Temps [s]
Manoeuvre parking CityPark CityPark parking maneuver
Consigne d’angle volant CityPark CityPark steering wheel angle setpoint

CityPark servo-control in CityPark parking maneuver
Consigne et mesure d’angle Volant CityPark CityPark steering wheel angle setpoint and measurement
Consigne d’angle CityPark CityPark angle setpoint
Mesure d’angle volant Steering wheel angle measurement
Temps (s) Time (s)
MISCELLANEOUS
No ventilation has to be applied on the EPS during all the test duration.

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N°101: EPS DURABILITY PERFORMANCE RELATED TO THE CITYPARK
FUNCTION AVAILABILITY
OBJECTIVE
Validate the durability performances related to the CITYPARK function.
TEST PARTS
Complete steering mechanism with functional assistance module and CITYPARK angle control
module.
Power supply.
Signal generator simulating the vehicle speed and engine state.
Signal generator simulating the CITYPARK communication messaging.
ASSEMBLY
The mechanism has to be fixed on a rigid support by its fasteners at nominal torque
The column linked to the mechanism has to comply with the vehicle installation.
The mechanism should be associated to a system creating a Fparking effort varying in function of the
rack position [A1115]
The voltage across the EPS terminals is specified in the associated requirement.
The steering wheel should be free. No torque should be applied to it.
CityPark cycle definition:

Sequence of 5 CityPark parking manoeuvres with 1 second between each parking maneuver (servo-
control at centre).
Cycle CityPark
600
400
Consigne d angle volant CityPark
200
-200
-400
-600
0 10 20 30 40 50 60 70 80 90
Temps [s]
Consigne d’angle volant CityPark CityPark steering wheel angle setpoint
Cycle CityPark CityPark cycle
Temps (s) Time (s)
MISCELLANEOUS
No ventilation has to be applied on the EPS during all the test duration.

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N°102: MIXED DURABILITY TEST FOR CITYPARK
OBJECTIVE
Validate the mechanical resistance and the wear levels of the steering system.
TEST PARTS
Steering mechanism (harness included).
Electric power supply.
Rack effort generator.
Rotating actuator
ASSEMBLY
The steering mechanism has to be fixed on a rigid support by its vehicle fasteners.
The mechanism is fitted on the bench in compliance with the different steering diagram points at the
vehicle installation (vehicle reference position).
The tie rods shall be set at the maximum of their length (minimum of threads inserted).
The tightening torques of the different assemblies shall be at the minimum of the tolerance range.
SOLICITATIONS
For the solicitations definition, refer to the test sheet 20 from page 51 to 58.
During the City-Park stresses, the setpoint following requirement
(BMPV/1V5_EPS_TS_SYSTEM_020) has to be met.

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N°110: STEERING WHEEL TORQUE IN CASE OF SHORT CUTS (PHASE/GND,
PHASE/+BAT, BETWEEN PHASES)
OBJECTIVE
To check that the product will not produce inacceptable steering wheel torque in case of short cuts between a
phase and the ground on one hand and between a phase and +bat on the other hand.
TEST PARTS
The tuning parameters of the EPS shall correspond to a real set of a known vehicle
ASSEMBLY
The EPS has to be linked to a system creating a constant force Fsi (see below).
LOADS
 The specified force is applied on the rack and the steering wheel is rotated according with the specified
profile until the rack end stop (right and left).
The steering wheel speed shall increase going from right rack end stop (resp left) to the left rack end stop
(resp right) so as to reach 720°/s
Proposal for steering wheel angle :
SW Angle [°] SW Speed [°/s]
600
650
400
450
Vitesse volant [°/s]

200 250
Angle volant [°]
50
0
0 2 4 6 8 10 12 14 -150
-200
-350
-400
-550
-600 -750
Tem ps [s]
 The power supplied shall be the worst regarding the EPS control. A voltage of 11,3V (worst case as for
avoidance maneuver) at the EPS harness shall be taken as a default value
 Test temperature = room temperature
 First test performed power off (no assist)
o With a rack force = 0.9*Fc
o With a rack force = 0.9*Fm
 The first sequence of test shall be performed with a rack force equal to 0.9*Fc, at a vehicle speed going
from 10 to 110 kph (with a 20kph step):
o At a regular power assist (according with the given vehicle speed value) [Power ON]
o With a short cut between two phases [CC2φ] and between three phases [CC3φ]
o With a short cut between a phase and the ground (resp. +Batt) [CC1φ]
The given short cut (simulated or real ) shall be detailed : impedance level, Mosfet failure, and it
shall be the one which involve the biggest customer effect (a batch on the impedance values can
be performed)
o With a short cut between a phase and the ground (resp. +Batt) with the countermeasure
[CC1φ+CM]
Nota : The supplier shall detail the countermeasure (ie reduced mode) applied in case of a
detected motor short cut (Design, SW, HW)
 A second test sequence is performed with a 0.9*Fc rack force, at a vehicle speed going from 10 to 110 kph
(with a 20kph step):
o At a regular power assist (according with the given vehicle speed value) [Power ON]
o With a short cut between two phases [CC2φ] and between three phases [CC3φ]
o With a short cut between a phase and the ground (resp. +Batt) [CC1φ]
o With a short cut between a phase and the ground (resp. +Batt) with a countermeasure [CC1φ+CM]
 A last test is performed power assist cut off and open motor phase [Open Phase]
The aim of the test is to evaluate the steering wheel torque without counter electromotive forces, that
simulate a Star Point Relay effect.
 Details on the tests
Vehicle Rack force Rack

SW speed
N° EPS state [daN] displacement
speed [°/s]
Cf §5 [mm]
[kph]
Rack End Stop
1Fc 0.9 * Fc
1Fm
Power OFF - 0 to 720
0.9 * Fm
to rack end
stop
2Vx Power ON
Vx =
3Vx CC1φ 0 to 720 0.9 * Fc RES to RES
10:20:110
4Vx CC1φ+CM
5Vx Power ON
Vx =
6Vx CC1φ 0 to 720 0.9 * Fm RES to RES
10:20:110
7Vx CC1φ+CM
8Fc_Vx Vx = 0.9 * Fc
CC2φ 0 to 720 RES to RES
8Fm_Vx 10:20:110 0.9 * Fm
9Fc 0.9 * Fc
CC3φ - 0 to 720 RES to RES
9Fm 0.9 * Fm
10Fc 0.9 * Fc
10Fm
Open Phase - 0 to 720
0.9 * Fm
RES to RES
OBSERVED DATA
 The supplier shall check that the rack force and steering wheel speed are consistent with the inputs values
 The sampling rate of measurement data shall show the whole steering wheel torque variation (in other
words: the sampling step shall be lower than 8 times the range to be plotted).
 The input shaft torque (Cp [Nm]) with respect to the steering wheel speed ( en °/s) shall be superimposed
on the same graph for each vehicle speed :
 {1Fc, 2Vx, 3Vx, 4Vx}
 {1Fm, 5Vx, 6Vx, 7Vx}
The mean torque values and ripple amplitudes have to be underlined on the graph.
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Nota: If necessary for visual convenience it will also be possible to present the results on 4 identical parts
as following:
Power ON Power OFF

CC1φ CC1φ +CM
 The input shaft torque (Cp [Nm]) with respect to the steering wheel speed ( en °/s) shall be superimposed
on the same graph for each vehicle speed :
 {1Fc, 3Vx, 9Fc, 10Fc}
 {1Fm, 6Vx, 9Fm, 10Fm}
The mean torque values and ripple amplitudes have to be underlined on the graph.
Nota : If necessary for visual convenience it will also be possible to present the results on 4 identical parts
as following :
Power OFF CC1φ

CC2φ CC3φ
 The gap between mean torques with respect to steering wheel speed shall be superimpose on the same
graph for each vehicle speed :
 {3Vx – 1Fc, 4Vx – 1Fc}
 {8Fc_Vx – 1Fc, 9Fc – 1Fc, 10Fc – 1Fc}
 {6Vx – 1Fm, 7Vx – 1Fm}

 {8Fm_Vx – 1Fm, 9Fm – 1Fm, 10Fm – 1Fm}
The gap of mean torque have to be underlined on this graph.

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6 APPENDIXES
6.1 APPENDIX 1: UNUSUAL EFFORTS
6.1.1 Usual life situations:
The indicated life situations are the followings:
Effort MAXI Incidental Accidental

Curb push Wheel front Wheel back Wheel front Wheel back
away impact impact impact impact
Impacts
120 10 10 1 1
number
6.1.2 MAXIMAL efforts (curbpush away)
Efforts for curb push away maneuver Ref BMPV A

Maximal force at the rack [kN] 1,883 1,883
Maximal traction force at the tie rod [kN] 1,68 1,68
Maximal compression force at the tie rod [kN] 1,44 1,51
The criteria that have to be applied for MAXIMAL effort tests are the following ones:
o no tie rod plastic deformation
o tightening torque loss lower than 20% during the assembly
The curb push away validation has to be initially done from a calculation file. In case of criteria excess, the
endurance test of bloc diagram type should validate the components.
The tests validate the tie rod (on housing side) and ball joint (on knuckle side) assemblies.
6.1.3 Wheel Impact Stress

These efforts come from calculations (performed with ATLAS SW), the criteria have been specified by taking into
account the results of the Wheel Impact tests with Instrumented Tie rod on a PMP Axle Type:
Reference

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Option BMPV A
Traction incidentel/accidental Incidental/Accidental traction
Compression incidental/accidental Incidental/Accidental compression
Déformation résiduelle de bielle admissible Allowed tie rod residual deformation
Effort de tenue de la bielle Tie rod resistance effort
The wheel front and back impacts

have to be specified by Forces
and Torques defined at the ball joint during incidental and accidental situation. The tie rod should be the fuse
part specified in the scenario of Wheel Impact on Front Axle.
Courbe d’Essai de Flambage de Biellette de Direction Test Graph of Steering Tie rod Buckling
Effort (daN) Effort (daN)
Déplacement (mm) Displacement (mm)

01452_13_00009 BMPV / 1V5 170/178
This notion of fuse part involves:
o For a minimal effort FA equal to a specified effort F1 (related to the VC1)
 the tie rod has to deform itself after the F1 effort application: its target residual length variation
(l1) is specified from the criteria of axle toe variations on the Vehicle Tests.
 the tie rod deformation, associated to a plasticity level and a location of this plastic deformation,
should not affect the tie rod life span
 the tightening torque loss at assembly level has to stay lower than 30 %.
 no torque loss on the toe adjustment nut
o For an effort FB equal to an effort F2 with a tolerance of +/-15% (linked to the VC2) :
 the tie rod has to deform from a target length variation, architecture data (l2) – this length
variation has to be sufficiently visible to involve a replacement of the assembled tie rod.
 the assemblies still have to exist (no steering tie rod breakage)
 tightening torque loss lower than 50 %.
 no torque loss on the toe adjustment nut
Thereby, it is necessary to ensure that:

F1 -10% < FA < F1 + 10% < F2 - 30% < FB < F2
At calculation, these life situations can be tackled with elastic and plastic approaches.
Note: The effort FA is more than 25% higher than the Curb push away Effort  Allows to have a reliable design of
the fuse part.
It is necessary to consider the 2 Steering Tie rod operating directions (traction & compression), particularly for the
Validation Tests.
To ensure a survivability of the result, it is necessary to test a minimal number of parts. For a reliable determination
of the tie rod resistance, the number of parts which have to be tested:
o 3 parts in Prototype Phase
o 9 parts in VRS Phase (by doing a parts selection in order to test 3 batches of 3 different parts according
to one or many decisive product or process parameters for the Tie Rod impact resistance, such as the
material spread / the rod diameter / … )
The necessary deliverables during the development are the followings:

o Mechanical characteristics of used materials:
 elastic-plastic laws for each component (for softwares like ABAQUS and RADIOSS)
 material characteristics RP0.2 / Rm / A%
o digital models of steering tie rods compliant with model specifications for the Crash and ACV (compliant
with the technical specifications: ILSI_AITR04_0830 )
o damage criteria used for the endurance calculations
Note: PSA can provide the data of the same type for the Knuckle.
Effort
Accél

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 Effort increasing speed
For information, the effort increasing speed on a wheel impact is between 30ms and 60ms. For information, the
steering tie rod temporal loading is given for a stress of Incidental type:
Effort
Acceleration

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 Validations by Calculations
It is possible to design parts for Wheel Impact by means of calculations. In that case Elastic-Plastic calculation laws
have to be used.
A model resetting with a simple test enable to check its representativeness.
Limit Conditions:
Fastening of Ball Joint type at point N.

Fastening of Sliding Ball Joint type at point M leaving free the MN axis.
Apply a displacement along the M-N axis up to Buckling by plastic deformation of the part. The calculation can be
done depending on the Traction and Compression direction.
Result:
Effort/Displacement graph at the Steering Tie rod level.

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Digital Criteria:
ACCIDENTAL
Fuse part:
 Functional criterion:
 No sudden part rupture
 Visible deformation of the part compliant with the requested value
 Tie rod residual length variation within the limits of the allowed deformation
 Digital criterion:
The supplier should use the digital criterion on which he has based his experience in agreement with
PSA.
If the supplier has not an associated criterion, the following criterion is suggested:
 Plastic deformation 0,25xA%  p 0,50xA% related to elastic-plastic calculations.

INCIDENTAL
Fuse part:
 Functional criterion:
 No component life span degradation after stress
 Visible deformation of the part compliant with the requested value
The supplier has to use the digital criterion on which he has based his experience in agreement with
PSA.
If the supplier has not an associated criterion, the following criterion is suggested:
 Plastic deformation 0,002xA%  p 0,06xA% related to elastic-plastic calculations

MAXIMAL EFFORT
 Physical criterion:
No local plastic deformation of the component under the considered stress.
The supplier has to use the digital criterion on which he has based his experience in agreement with
PSA.
If the supplier has not associated criterion, the following criterion is suggested:
 VM < Rp0.2 (minimal yield limit of the material) according to a calculation with behavior laws of elastic
materials.

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6.2 APPENDIX 2: LIST OF THE QUOTED PSA STANDARDS
Resistance to the mechanical environment: B21 7120
Code Description Class Precisions
B21 7120
CONNECTING COMPONENTS
M1.1 tabs A
M1.2 connectors A
FASTENERS
M2.1 external efforts for the A
device
M2.2 accelerations generated by NA
the device
IMPACTS
M3.1 ball drop A
M3.2 rocker A
M3.3 free drop A
GRITTING
M4 gritting resistance test A
VIBRATIONS
M5.5 sprung mass device (or on A
body)
NOISE
M6.1 measurement in anechoic NA
chamber

01452_13_00009 BMPV / 1V5 175/178
Climatic and chemical environment resistance B21 7130
Code Description Classe Precisions
B21 7130 Description Class
TEMPERATURE TEST
CL01 Operating after storage A
CL02 Out of operating temperatures A
CL03 Operating extreme temperatures at usual supply A
voltages
CL04 Temperature steps A
CL05 Unusual voltage supply A
CL06 Self-heating measurement A
CL07 Ageing by air/air thermal shocks A
CL08 Thermal cycle durability A
CL09 Activation durability A
CL10 High temperature durability NA
CL11 Determination of the operating limits in temperature NA
HUMIDITY, SEALING AND CHEMICAL TESTS
CL12 Humidity and corrosion outside the vehicle A
CL13 Protection ensured by envelops (IP) A
CL14 Immersion in vacuum pressure. A
CL15 Iced water thermal shocks A
CL16 High pressure washing A
CL17 Operation with dust A
CL18 Exposures to acid vapors NA
CL19 Accidental penetration of liquid in the equipment A
ELECTRICAL TESTS FOR CHARACTERISATION
CL20 et Dielectric resistance and insulation resistance A
CL21
CL22 Voltage drop A
MATERIAL TESTS
CL23 Fire resistance V0 and
SE
CL24 Printed circuit characterization (PCB) A
CL25 Occasional contacts with auto fluids A
CL26 Characterization according to the PSA specification A
B62 0030
CL27 Dirtiness inside the passenger compartment NA

01452_13_00009 BMPV / 1V5 176/178
6.3 APPENDIX 3: ANALYSIS PROCEDURES
Reference Application
CPBM_CMPM06_0087 New part analysis
New parts analysis is necessary and mandatory:
- Allows to specify weak points on function
- Allows to guarantee compliance with drawings
- Allows to specify the manufacturing quality (cleanliness, defect due to the manufacturing
process)
- During an analysis of a defective part during customer using and/or during running, the new
part analysis becomes the reference.
- It is necessary and mandatory to perform an analysis of a new part before any validation test.
Then the analysis has to be done on a part from the same manufacturing batch as those which
should be validated. The results should be used as indicators.
CPBM_CMPM06_0088 Analysis after corrosion test
The corrosion phenomena bring kinetic mechanisms, the part after an accelerated corrosion
test could still be functional, despite the presence of important corrosive cracks or material
ageing. The accelerated corrosion tests are too fast to enable mechanisms to stabilize and so
to create a functional risk.
Analyses allow to make plan for risk suppression and to evaluate the functional risk related to
incipient cracks observed after tests.
CPBM_CMPM06_0089 Analysis after vibration tests
CPBM_CMPM06_2167 Plastic material analysis
CPBM_CMPM06_2169 Analysis of cracking detection/measurement on plastic boxes
This procedure is used after corrosion tests:
- running tests of steering wheel angle sensor type
- environmental tests of the B217130
- natural corrosion tests
- BS or Swaat test type
- duplication tests of the seasonal crack phenomenon
CPBM_CMPM06_2168 Metallic material analysis
This procedure describes the logic sequence of an analysis. No modification should be allowed.
However, others analysis methods can be used if they are explained in analysis reports.
The main purpose of this document is to describe the analysis methods and agreements
validated and used by PSA.
CPBM_CMPM06_0090 Analysis after contactor activation (contact grain)
CPBM_CMPM06_2338 Analysis of the crimping areas on the E/E function clips and tabs
CIMB_IMPM09_0286 Guide for preventive analysis of mechanical part built in organic

material
The result validation of the analyses performed by the supplier should be performed by PSA material departments.

01452_13_00009 BMPV / 1V5 177/178
6.3.1 List of deliverables
In addition to usual recipients, all documents required in this specification must be transmitted to the material and
process pilot of PSA project team.
Document(s) waited or Where the elements must

Requirement Stage of project
concerned. appear
Before prototype & serial Technical response to RFQ
ED__01 Supplier drawing tool manufacturing Supplier drawing Project review minutes
launch DEVIN
In response to RFQ Technical response to RFQ
Detailed material Detailed material
ED__02 and after each Project review minutes
nomenclature nomenclature
modification Q3P grid
Quality response to RFQ
ED__03 Manufacturing flow chart In response to RFQ Manufacturing flow chart Project review minutes
Q3P grid
Material certificate of Before prototype & serial Material certificate of
ED__04 Design review documents
compliance tooling realisation launch compliance
Before process Supplier process
ED__05 Process parameters Appendices of B20 1310
qualification qualification document
Before prototype & serial
ED__06 Rheological study tooling manufacturing Study report
launch Design review documents
Before prototype & serial Project review minutes
Dimensioning by
ED__07 tooling manufacturing Calculation report
calculation
launch
Before prototype & serial
Material certificate of Conception review
EN__01 End of life vehicle tooling manufacturing
compliance documents
launch
B62 0300 (material
EM__0
adequation to its
1
environment) In response to RFQ Technical response to RFQ
Detailed material
EM__0 and after each Project review minutes
PSA material policy nomenclature
2 modification Q3P grid
EM__0
« green » materials
3
In response to RFQ
EM__0 Products used for making Project review minutes
and after each Supplier recommendation
4 assembling easier Q3P grid
modification (if needed)
Design file
EM__0 On IOD (from final
Marking Supplier drawing CR project review
5 tooling) parts
Then DEVIN
EM_06 Rubber volume resistivity In response to RFQ Test report Technical response to RFQ
EM_10
B20 4100 In response to RFQ Test report Technical response to RFQ
1
EM_10 Material compatibility Technical response to RFQ
In response to RFQ Test report
3 (rustled noise) Q3P grid
ET__01 Sampling of test parts At each test
ET__02 Material quality evaluation
Material quality evaluation
ET__03
of welding beads
ET__04 Behavior to impact In prototype phase and
during industrialization
ET__05 Multi-material architecture PIV
phases PIV
Resistance to occasional Test reports
ET__06 (details are to be
fluids
determined during the
ET__07 Thermal ageing Tpeak
initialization review)
ET__08 Thermal ageing Tcontinius
ET__10 Thermal shocks
ET__11 Climatic cycles

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REFERENCE IND PROJECT PAGE

Index Date Modifications type

OR V1.0 14/01/2013 Creation

V2.0 Removal of temperature values, replacement by acronyms : TminHF, TminEF,

REFERENCE IND PROJET PAGE

REFERENCE IND PROJET PAGE

REFERENCE IND PROJET PAGE

This document applies to:

AEE2004 Merco AEE2010 Evo

2.1.2 System limits

REFERENCE IND PROJET PAGE

2.1.3 Situations of life

2.1.4 Context of use for the product

FS 01.1: Allow the driver to steer the vehicle;

FC 01: Comply with standards.

REFERENCE IND PROJET PAGE

3.1.2 Vehicle Functional Requirements

ST Véhicule - Diriger le Véhicule et Assister la No

3.1.3 French and international standards

3.2 APPLICABLE DOCUMENTS

[A004] 01552_12_10540 Dossier de consultation software EPS Yes

[A1020] DA_MQF05_0015_EX_En_V005 Plan Type PCP Yes

[A1021] DA_MQF05_0002_EX_En_V006 Inspection report template Yes

[A1022] DTI_DQI08_0020 Mass production evolution management Yes

[A1023] Standard management of a Supplier request for a Yes

[A1100] 01446_12_00049 Dossier d'exigences Diagnosticabilité Yes

[A1110] Tbd Objectifs qualité EPS Yes

[A1111] 01452_13_00063 EPS Specification rack load vs rack travel Yes

[A1121] 02016_12_09367 DC_TI_70_Reprogrammation_des_UCEs Yes

[A1122] 01552_13_00739 ST FH CAN Yes

[A1127] 00998_12_00471 DAE Additive CityPark Function TS Yes

[A1128] 01452_13_00053 Tableau de suivi de durabilité Yes

[A1129] 00998_12_01589 LKA Function TS Yes

[A1130] ILSI_CSLS06_0421 Cdc_EPS_Modelisation Yes

[A1131] BMPV_Specification_Safety_Req_Inputs- Yes

[A1133] 01452_13_00067 DIA SDF EPS Yes

[A1134] 01552_13_01129 ST gestion multi-mode Yes

3.2.2 European guidelines

Directive européenne relative au marquage des pièces et des Yes

REFERENCE IND PROJET PAGE

AA36859283 EPS 3D functional B-MPV DàG Yes

AA36859660 EPS 3D functional B-MPV DàD Yes

[A4010] AA36944699 EPS 3D functional 1V5 DàG Yes

AA36944700 EPS 3D functional 1V5 DàD Yes

01452_13_00069 EPS functional drawing Yes

[A4030] 01452_12_00143 Geometry for Grii Noise masselote Yes

[A4020] 01552_13_00738 ST Fonctions & Interface EPS Yes

3.2.4 French and international standards

[A2082] NF EN 1563 Fonderie-Fonte à graphite sphéroïdale No

[A2090] NF EN ISO 1110 Plastiques - Polyamides - Conditionnement No

3.2.5 PSA standards

REFERENCE IND PROJET PAGE

A12 5510 Véhicules hors d’usage (VHU) – Aptitude à la dépollution du

REFERENCE IND PROJET PAGE