Industry Insight

SbW System in Electric Vehicles: Detailed Explanation The Steer-by-Wire (SbW) system is a cutting-edge technology that significantly improves the steering mechanism in modern vehicles, particularly in the realm of electric vehicles. Traditional steering systems are mechanical, where the driver manipulates the steering wheel, transforming movement to the steering wheels via linkages and steering mechanisms. The SbW system, however, eliminates this mechanical connection, relying entirely on electrical signals to control the steering. This technological shift unlocks new possibilities for vehicle design and performance, enabling more precise, customizable steering characteristics and greater vehicle safety. 1. Overview of the SbW System The SbW system consists of three core components: steering wheel assembly, steering actuator assembly, and main controller (ECU). Additional systems, such as fail-safe mechanisms and power supply systems, support the overall functionality and reliability of the system. 2. How the SbW System Works The SbW system operates by detecting the driver’s steering intentions through sensors. These data points are then transmitted via a data bus to the vehicle’s ECU, which processes the information and sends feedback commands to the steering actuator system. This system controls the movement of the wheels, ensuring they reach the required angles. The steering angle and torque feedback are sent back to the system, completing the cycle of control. 3. Key Features of the SbW System 1. Enhanced Automotive Safety Performance The SbW system removes mechanical components like the steering column, reducing the risk of injury during collisions. The intelligent ECU continuously monitors the driving conditions, adjusting the system to ensure optimal safety. In extreme conditions, the system can stabilize the vehicle automatically. 2. Improved Handling and Maneuverability The SbW system dynamically adjusts the steering ratio based on driving parameters such as speed, traction, and road conditions. At low speeds, the steering ratio is reduced, requiring less wheel rotation for tight turns and parking. At higher speeds, the ratio increases for improved stability and handling during straight-line driving. 3. Enhanced Road Feel for Drivers Without a mechanical connection between the steering wheel and the wheels, the SbW system uses simulated feedback to provide drivers with a realistic “road feel.” This feedback is derived from the vehicle’s actual driving and road conditions, ensuring that only useful information is relayed to the driver, resulting in a more natural driving experience. 4. Advantages of the SbW System Improved Handling Stability: The SbW system synchronizes the steering wheel and actuator, allowing for more responsive and precise control, which enhances driving stability. Enhanced Comfort: By eliminating vibrations caused by uneven surfaces or imbalances in the steering mechanism, the SbW system provides a smoother, more comfortable ride. Energy Efficiency: The SbW system only activates during steering input, optimizing energy consumption and contributing to improved fuel efficiency and eco-friendliness. Increased Passive Safety: In the event of a collision, the SbW system significantly reduces the impact force transmitted through the steering column, enhancing driver safety. Weight Reduction: By eliminating the mechanical linkages, the SbW system reduces vehicle weight by approximately 5 kg, contributing to vehicle light-weighting efforts. 5. Challenges for the SbW System Power Requirements: The SbW system requires high-power actuators and complex algorithms to ensure accurate force feedback and steering control. Reliability and Safety Concerns: As with any new technology, improving the safety and reliability of the SbW system remains a critical focus for automotive manufacturers. Increased Cost: The inclusion of redundant components and advanced sensors can increase the cost and weight of the system, which may present challenges in mass adoption. 6. Future Trends of the SbW System The rise of intelligent driving technologies and the growing popularity of electric vehicles positions the SbW system as a key component in future vehicle designs. With advancements in autonomous driving and smart vehicle technologies, SbW is expected to become a mainstream solution, offering drivers a more accurate, safe, and comfortable driving experience. Ongoing research and development by automotive manufacturers will continue to drive innovations in SbW technology, unlocking new possibilities for the automotive industry. Brogen Steer-by-Wire Technology At Brogen, we offer a customized steer-by-wire system specifically developed for autonomous vehicles, adaptable to multiple operating modes (mechanical mode, power-assisted mode, and angle control mode). Our solutions are designed to meet the diverse needs of different customers, offering various design options such as electric power assistance and intelligent driving. Our series of SbW products feature high intelligence and integration, making them ideal for applications in human-machine collaboration, autonomous driving scenarios, and various layout configurations. Currently, our SbW products are being utilized in low-to-medium speed autonomous vehicle chassis, supporting commercial applications in driverless logistics and autonomous urban distribution. Support seamless transitions between human-machine collaboration modes in autonomous vehicles. Deliver rapid steering response with a latency of less than 50 ms. Manage steering angle overshoot effectively. Ensure precise steering control accuracy. Allow for steering angle and angular velocity control commands to be transmitted via bus communication, independent of manual electromechanical systems. Learn more here: https://brogenevsolution.com/steer-by-wire-sbw-system-oem-odm-manufacturer/ Business inquiry: contact@brogenEVSolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype,

Top 4 Trends in Automotive Steering Systems in 2025 Steering systems are one of the most essential components of any vehicle, impacting safety, control, and efficiency. As automotive technology continues to evolve, so do the demands on them, particularly with the rise of electric vehicles (EVs). Let’s explore the current trends shaping the future of automotive steering systems, with a focus on Electric Power Steering (EPS), Steer-by-Wire (SbW), and innovations designed to improve vehicle performance, safety, and comfort in 2025 and beyond. 1. Widespread Adoption and Optimization of Electric Power Steering (EPS) The adoption and optimization of Electric Power Steering (EPS) will become a mainstream trend in the automotive industry. With the growing popularity of electric vehicles, EPS will see expanded use due to its high efficiency and energy-saving features. In the coming years, EPS technology will be further refined to reduce energy consumption and enhance response speed. Additionally, EPS will be integrated more deeply with other vehicle electronic systems, such as brakes and suspension, for more efficient coordinated control. Moreover, Steer-by-Wire technology, which replaces traditional mechanical connections with electronic signals, will also make significant advancements. This will improve steering precision and response times, while providing safer steering control for autonomous vehicles. 2. Intelligent and Adaptive Steering Systems The trend towards intelligent and adaptive steering systems will play a critical role in the future of automotive technology. Steering systems will evolve to automatically adjust steering force and feedback based on driver habits, road conditions, and vehicle speed, offering a more personalized driving experience. By integrating sensor technology and artificial intelligence (AI), these systems will be able to detect real-time road conditions, such as slippery surfaces or obstacles, and automatically adjust steering strategies to improve safety. These adaptive systems will be deeply integrated with autonomous driving technologies, enabling precise path tracking and obstacle avoidance. Additionally, redundant designs will ensure that these systems continue to function effectively even if part of the system fails, enhancing both safety and reliability. 3. Focus on Energy Efficiency, Sustainability, and Personalized Comfort As environmental concerns and fuel efficiency remain at the forefront of automotive development, future steering systems will place increased emphasis on energy efficiency and sustainability. Steering systems will be designed to reduce the load on vehicle powertrains, particularly in electric vehicles, which require maximum battery efficiency. Moreover, eco-friendly materials will be incorporated into the design of steering systems to minimize environmental impact. Beyond energy conservation, personalized comfort will be a key focus. Steering systems will allow drivers to choose from different steering feedback modes, such as sport or comfort, based on personal preference. In addition, smarter power assistance will help reduce driver fatigue, especially during long drives.  On the safety front, steering systems will be equipped with fault detection and self-repair capabilities. These systems will also be integrated with ADAS (Advanced Driver Assistance Systems) to offer lane-keeping, automatic obstacle avoidance, and other active safety features. 4. Advanced Materials, New Manufacturing Processes, and Vehicle Connectivity The application of new materials and advanced manufacturing processes will play a pivotal role in the continued innovation of steering systems. Lightweight, high-strength materials such as carbon fiber and aluminum alloys, along with cutting-edge technologies like 3D printing, will enable the creation of more complex and reliable steering components, leading to enhanced performance. Additionally, steering systems will benefit from increased vehicle-to-vehicle (V2V) and vehicle-to-infrastructure (V2X) connectivity, enabling collaborative steering control across connected vehicles. Cloud-based data analysis will allow for real-time optimization of steering strategies, adapting to various driving environments and enhancing overall performance and safety. Conclusion: Steering Systems in 2025 and Beyond By 2025, automotive steering system will be more intelligent, efficient, and sustainable than ever before. From the widespread adoption of Electric Power Steering (EPS) to the breakthrough advancements in Steer-by-Wire technology, the future of steering is set to offer a more responsive, personalized, and safe driving experience. The integration of AI, adaptive features, and eco-friendly materials will redefine how we interact with vehicles, while vehicle connectivity and advanced manufacturing processes will push the boundaries of steering performance and reliability. As the automotive industry moves toward greater sustainability and automation, steering systems will continue to evolve, playing a pivotal role in shaping the future of electric mobility and autonomous driving. How Can We Help? At Brogen, we specialize in the development, production, and sales of electric power steering solutions for the automotive industry since 2007. Our power steering system range has expanded from hydraulic systems to electric solutions like EHPS, eRCB, EPS, and SbW, with over 2,500 models for both traditional and electric vehicles. In response to the growing demand for commercial vehicle steering upgrades, we’ve focused on developing EPS systems for light, medium, and heavy commercial vehicles, achieving mass production through continuous R&D innovation. Brogen EPS Factory Energy efficient Light and responsive steering Flexible system layout Low noise, high comfort, and active safety Fast matching and rapid development Compatibility with ADAS and autonomous driving Learn more here: https://brogenevsolution.com/electric-power-steering-solutions/ Business inquiry: contact@brogenEVSolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact

Electronic Differential Lock (EDL/EDS): Technology Overview What is Electronic Differential Lock or System (EDL/EDS)? An Electronic Differential Lock or System (EDS/EDL) refers to the use of electronic control to manage the speed of the left and right wheels, enabling them to rotate at different speeds. This system adjusts the speed or torque of the drive motors independently for each wheel, allowing the vehicle to steer effectively while turning. Essentially, EDS optimizes torque distribution between wheels for efficient and stable maneuvering, particularly in vehicles with distributed drive systems. Different Ways to Achieve Electronic Differential and Their Pros & Cons The key challenge in differential steering is ensuring the wheel rotational speed matches the speed of the wheel‘s axle to prevent skidding or dragging. In traditional central-drive vehicles, mechanical differentials coordinate the wheel speeds. However, distributed drive vehicles, where the left and right drive wheels are not mechanically connected, rely on electronic differential control to solve this problem. There are two primary methods for implementing EDS: Wheel Speed-Based Control: This method controls the wheel speed and can use the Ackermann-Jeantand steering model. It calculates the theoretical speed of the left and right drive wheels in real time and controls them accordingly. This approach is simple but has significant limitations and can cause vehicle instability and excessive tire wear. When driving on uneven terrain, the suspension’s vertical movement can cause a mismatch between the real and theoretical wheel hub speeds, which degrades the control effect, resulting in inconsistencies in the wheel speed control and potential slip or drag. Additionally, during high-speed turns, tire lateral slip characteristics significantly change compared to low-speed scenarios, making the Ackermann model unsuitable for control, and wheel speed control can impact vehicle stability. Ackermann-Jeantand steering model Wheel force Motor Torque-Based Control: This method uses the drive wheel motor torque as the control variable, instead of controlling wheel speed, allowing the wheels to rotate freely according to their load. Since each drive wheel can rotate independently, as long as the wheel-tire-road friction does not exceed the limit, the friction force on the road will balance the driving force. In the stable range of tire attachment characteristics, road friction is a monotonous function of slip ratio, meaning there is a direct correspondence between friction force and slip ratio. As long as the motor torque does not exceed the attachment limit, the slip ratio remains within the stable region of tire attachment characteristics, and no differential issue arises, preventing wheel slip or drag. When the motor torque exceeds the friction limit, wheel slip will occur, and anti-slip control will be activated. This method can implement adaptive differential steering, where the control system outputs motor torque commands based on the vehicle’s motion state, and the wheel speed is determined by the tire force balance. This method, combined with anti-slip control, performs well for electronic differential functions, but its control algorithms become more complex as driving conditions change. Increasingly, researchers prefer using motor torque as the control variable, which is closely linked to anti-slip research. Electronic differential research based on torque control and anti-slip technology is an integrated field, and many scholars worldwide have explored this from the perspective of vehicle dynamics control. Current Development of Commercial Vehicles Compared to passenger cars, the advantages of distributed drive systems are more evident in commercial vehicles. First, the high integration of distributed drive systems enables low-floor, wide-passenger designs for city buses, facilitating quick and barrier-free transit, especially in large and medium-sized cities with an aging population, making distributed drive buses increasingly popular. Additionally, by eliminating mechanical differentials and drive shafts, lightweight independent suspension and single-tire configurations can be used, improving system efficiency. Lastly, distributed drive systems allow for independent, precise, and continuous control of drive and braking forces for each drive wheel, fully utilizing tire-road friction characteristics and enabling traction control, anti-lock braking, and stability control. Based on these advantages, the promotion of distributed drive technology in city buses is on the rise. Engineering Development Process for Distributed Drive Electronic Differential Lock The engineering development process for distributed drive electronic differential control technology follows the V-model, from initial function definition and requirement analysis to final application and mass production. The V-model emphasizes collaboration and speed in software algorithm development, integrating algorithm implementation and verification, shortening the development cycle while ensuring high-quality software algorithms. The development process consists of two phases: the software algorithm development phase and the product testing phase. At the start of software algorithm development, requirements are defined, including market demands and product functionalities. After understanding these requirements, designers can proceed with system architecture and product functionality design. The algorithm development team will then create models and simulations, using Matlab for algorithm design. Offline simulations, including model-in-loop and software-in-loop simulations, are performed before downloading the algorithm to rapid prototyping devices for online simulation and algorithm verification.  After this, the software-generated C code is tested with the ECU on a test bench. Once the software and hardware are tested, control parameters are optimized during real-world road testing. This includes calibrating the vehicle’s performance to its best state and conducting reliability tests over a set distance. After completing the above steps, the product can be mass-produced and launched into the market, with continuous feedback for algorithm optimization and upgrades. Each step in the process is crucial for ensuring reliable products and functionality. Project Development Personnel, Timeline, and Budget 6.1 Personnel Compared to traditional central drive systems, the development of distributed drive systems involves more complexity due to the harsh operating environment of the motors. This requires a broader range of expertise. For example, the development of the new energy system involves roles such as: 2 people for gearbox design 2 people for motor design 1 person for motor controller matching 1 person for power system performance and efficiency matching 2 people for vehicle control strategy development 1 person for vehicle calibration, etc. In the chassis design, roles include: 1 person for axle design 2 people for suspension design 1 person for brake design 1 person