Dynamic Testing Solutions

2. Commercial Vehicle and Conventional Steering System Testing Solutions
3. Industry Background & Engineering Challenges

Commercial vehicle and conventional steering systems are evolving toward electronic control and steer-by-wire, driven by the implementation requirements of vehicle electrification and high-level autonomous driving to achieve higher efficiency, precise control, and system integration.

Constantly changing new requirements present additional challenges during the testing and validation phase:

• Validation of cooperative operationamong multiple systems transitioning from hydraulic to electro-hydraulic
• Safety and redundancy validationof steer-by-wire systems under extreme conditions
• Constantly evolving new requirements bring more challenges to the testing and validation phase
• Repeatable and quantifiable testingfrom component level to system level
• Equipment requiring greater intelligence, smaller footprint, higher energy efficiency, and lower noise

For OEMs and Tier 1 suppliers, the core issue is no longer “whether testing means exist,” but rather: Can we continuously validate and improve authentically, controllably, and reproducibly in the early stages of development?

2. KTS System-Level Approach

From a “complete commercial vehicle system testing” perspective, KTS has built a system covering:

Hydraulic Pump Testing → Hydraulic Cylinder Testing → Hydraulic Recirculating Ball Testing → Electric / Electro-Hydraulic Recirculating Ball Testing → Redundant Electric Recirculating Ball Testing → Integrated Steering-Brake HIL Testing

• This system consists of the following three layers of capability:
• High-precision actuation and high-load loading capabilities
• Multi-channel synchronous measurement and precise control capabilities
• Test condition modeling and data capabilities

These ensure that test results are not only “measurable” but also credible, benchmarkable, and usable for design decisions.

3. Core Testing Capability Modules
4. Electric / Electro-Hydraulic Recirculating Ball System Testing

• System assist characteristic and response testing
• Returnability and hysteresis characteristic evaluation
• Active steering, smart steering redundancy, and failure condition validation
• Multi-variable synchronous loading and measurement including torque, angle, force, operating current, and operating oil pressure

Applicable for:

Hydraulic recirculating ball assemblies and components

Electric recirculating ball assemblies and components (X-EPS)

Electro-hydraulic recirculating steering gear assemblies and components

2. Steering Pump and Industrial Control Servo Pump System Testing

• Pump displacement testing
• Pump pressure holding testing
• Pump durability testing

Applicable for:

• Steering pump performance testing
• Steering pump durability testing
• Industrial control servo pump testing

3. Fully Hydraulic System Testing

• Performance of assist cylinders under different pressures
• Adjustable pressure and temperature of the assist pump station
• Synchronous high-speed acquisition of hydraulic pressure, output force, etc.
• Precise control under multiple complex conditions

Applicable for:

• Assist cylinder testing

4. System-Level and HIL Joint Testing

• Joint closed-loop testing of steering and brake systems
• Hardware-in-the-loop co-simulation with vehicle control strategies
• Virtual validation of extreme and fault conditions
• By combining HIL with physical actuation systems, “road test risks” are shifted forward to be completed within the laboratory.

4. Key Technical Advantages

High-dynamic, high-precision actuation system

• Servo loading system with high-bandwidth response capability
• Supports force / displacement / torque multi-mode control
• Meets high-frequency dynamic and impact condition testing requirements

Multi-channel synchronous control and measurement

• Strict synchronization across multiple axes and channels
• Supports complex coupled conditions
• Ensures authenticity and consistency of system-level testing

Test conditions can be modeled and reproduced

• Supports modeling of typical roads, operating conditions, and custom conditions
• Test processes are repeatable, replayable, and comparable
• Suitable for design validation and regression testing

Custom-oriented system integration capability

• Customized according to customer chassis architecture and development stage
• Supports bench testing, production line testing, and R&D testing
• Can integrate with customer’s existing software and control platforms

5. Typical Application Scenarios

• Vehicle manufacturer chassis system R&D and validation
• Including China National Heavy Duty Truck Group, Shaanxi Automobile Group, FAW Group, etc.
• Tier 1 steering / brake system development
• Zhejiang Shibao, Yubei Steering Systems, Henglun Group, Weihai Tianrun, Guotaiyang
• New steer-by-wire chassis architecture validation
• Early-stage testing of new vehicle platform development
• Rapid regression validation after design changes

6. Implementation & Delivery

KTS provides complete engineering services from requirements analysis to system delivery:

Test requirements and condition analysis

System solution design and simulation validation

Equipment manufacturing and system integration

On-site installation, commissioning, and training

Long-term technical support and system upgrades

7. Selected Case Studies
8. Electric / Electro-Hydraulic Recirculating Ball System Testing

Capable of completing testing for electro-hydraulic recirculating ball steering gears, electric recirculating ball steering gears, and conventional pure hydraulic recirculating ball steering gears. Test items include all test items for both hydraulic recirculating ball steering gears and electric recirculating ball steering gears.

Intelligent electro-hydraulic recirculating ball steering gears retain the advantages of conventional recirculating ball hydraulic power steering gears while adding automatic control and active steering functions through the electric assist portion, representing one of the key technologies for achieving intelligent driving and autonomous driving in trucks.

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2. Steering Pump and Industrial Control Servo Pump Testing System

The system is capable of conducting performance testing and reliability testing for various types of automotive hydraulic steering power pumps, electro-hydraulic steering power pumps, and industrial control servo pumps.

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3. System-Level and HIL Joint Testing

The HIL testing solution for commercial vehicle intelligent steering and brake systems uses a real-time simulator to simulate vehicle dynamics and sensor environments, connected to actual steering/brake controllers. The core objective is to validate control logic, actuator response, and system fault diagnosis and handling capabilities under complex operating conditions, ensuring functional safety and reliability.

This solution has been successfully applied in multiple steering, braking, and steer-by-wire chassis system development projects for various OEMs and Tier 1 suppliers, significantly improving testing efficiency and validation depth in areas such as system dynamic consistency and safety validation.

8. Contact & Customized Solution

If you are currently developing chassis systems or steer-by-wire chassis-related products, please contact the KTS engineering team. We will provide you with:

• Testing solution recommendations tailored to your specific system architecture
• Customized test system design
• Engineering-level technical communication and support