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ROLL NO :08614803609

NEW DELHI-110086


I take immense pleasure in thanking Mr. P.K. ARORA
(General Manager) and MR. NILESH SHARMA
(Production Manager) for having permitted me to carry
out this project work.
I wish to express my deep sense of gratitude to Mr.
LOVENEET GROVER for his able guidance and useful
suggestions, which helped me in completing the project
work in time.
Words are inadequate in offering my thanks to the
Project Trainees and Project Assistants, MEAI for their
encouragement and cooperation in carrying out the
project work.

Contents: Introduction To MEAI

Introduction To EPS Motor
Production /Assembly
Advantages of Using EPS

Mitsubishi Electric Automotive India

Its operations began in India in the mid-1950s, now
Mitsubishi Electric has grown to become one of the
most highly regarded companies in this country.
The Mitsubishi Electric Automotive India ,
operates on the corporate principle of contributing
to creating a vibrant and affluent society by
enhancing its technologies, services, and creative
powers, as a leader in the manufacture and sales of
electric and electronic equipment used in Energy
and Electric Systems, Industrial Automation,
Information and Communication Systems,
Electronic Devices, and Home Appliances.
Guided by their corporate statement, 'Changes for
the Better,' they take their responsibility as a
corporate citizen very seriously. Its products are
developed with superior energy efficiency and the
environment in mind .

Production lines at MEAI are :1.Immobilizer line assembly

2.EPS ECU assembly line
3.EPI ECU assembly line
4.EPS motor line
5.Distributor line
6.Starter line

EPS Motor :Electric power steering works with the

help of an Electric Motor , called Electric power
steering (EPS) motor and a control unit which has
some sensors , called electric contol unit (ECU).
The motor runs on battery and will use electric
power to assist the movement of steering when the
driver turns the wheel.
For many drivers, turning the steering wheel in a
vehicle that doesn't have power steering requires
more force torque than the driver finds
comfortable, especially when the vehicle is moving
at a very slow speed. Steering force is very
sensitive to the weight of the vehicle, and nearly so
much to its length, so this is most important for
large vehicles. In a vehicle equipped with power
steering, when the driver turns the steering wheel,
she or he feels only a slight retarding force, so a
vehicle equipped with power steering can be driven
by any healthy driver, even when the vehicle is
being parked. This is because the power steering
system furnishes most of the energy required to
turn the steered wheels of the car.

Conventional power steering systems use an engine

accessory belt to drive the pump, providing
pressurized fluid that operates a piston in the power
steering gear or actuator to assist the driver.
In electro-hydraulic steering, one electrically
powered steering concept uses a high efficiency
pump driven by an electric motor. Pump speed is
regulated by an electric controller to vary pump
pressure and flow, providing steering efforts
tailored for different driving situations. The pump
can be run at low speed or shut off to provide
energy savings during straight ahead driving
(which is most of the time in most world markets).
Direct electric steering uses an electric motor
attached to the steering rack via a gear mechanism
(no pump or fluid). A variety of motor types and
gear drives is possible. A microprocessor controls
steering dynamics and driver effort. Inputs include
vehicle speed and steering, wheel torque, angular
position and turning rate.

Electric Power Steering has the advantages of

safety, energy saving, environmental protection and
so on. It has become the mainstream of power
steering technology for passenger cars because of
the important role of improvement of portability
and the enhancement of handling stability and


Front bearing press fit & stacking

One side dust collection
Housing dust collection
Brush holder installation
Brush holder assy screw tightening
Brush holder screw re-tightening
Armature assy,dust collection & press fit
Body assy dust collection & press fit
Boss assy dust collection & press in
Rear bearing press fit
Thrust rattle check
Armature assy , dust collection & pigtail
& silicon assembly
Grease application

Magnet dust collection & assembly

Magnet assy & magnetisation of yoke
Yoke assy installation and screw
Yoke assy screw tightening torque check
Performance test :1.Running in test
2.Withstand voltage test

3. No load test
4.Load test
5.Loss torque test
Bears run out test & adjustment
Vibration test
Noise check & appearance check
Air tight test

Working :EPS motor consumes energy only when power

assist is required .It is not dependent on the
engine for its power source so steering feel is
not affected when the engine is shut off.
The EPS ECU uses the torque sensor output
and information from the skid control ECU
about vehicle speed and torque assist demand
to determine the direction and force of the
power assist .It then actuates the EPS motor
A "steering sensor" is located on the input
shaft where it enters the gearbox housing. The

steering sensor is actually two sensors in one:

a "torque sensor" that converts steering torque
input and its direction into voltage signals, and
a "rotation sensor" that converts the rotation
speed and direction into voltage signals. An
"interface" circuit that shares the same housing
converts the signals from the torque sensor and
rotation sensor into signals the control
electronics can process.
Inputs from the steering sensor are digested by
a microprocessor control unit that also
monitors input from the vehicle's speed sensor.
The sensor inputs are then compared to
determine how much power assist is required
according to a preprogrammed "force map" in
the control unit's memory. The control unit
then sends out the appropriate command to the
"power unit" which then supplies the electric
motor with current. The motor pushes the rack
to the right or left depending on which way the
voltage flows (reversing the current reverses
the direction the motor spins). Increasing the
current to the motor increases the amount of
power assist.
The system has three operating modes: a

"normal" control mode in which left or right

power assist is provided in response to input
from the steering torque and rotation sensor's
inputs; a "return" control mode which is used
to assist steering return after completing a
turn; and a "damper" control mode that
changes with vehicle speed to improve road
feel and dampen kickback.
If the steering wheel is turned and held in the
full-lock position and steering assist reaches a
maximum, the control unit reduces current to
the electric motor to prevent an overload
situation that might damage the motor. The
control unit is also designed to protect the
motor against voltage surges from a faulty
alternator or charging problem.
The electronic steering control unit is capable
of self-diagnosing faults by monitoring the
system's inputs and outputs, and the driving
current of the electric motor. If a problem
occurs, the control unit turns the system off by
actuating a fail-safe relay in the power unit.
This eliminates all power assist, causing the
system to revert back to manual steering. A

dash EPS warning light is also illuminated to

alert the driver.

ADVANTAGES : Electric systems have an advantage in fuel

efficiency Because the electric power steering
system (EPS) engages the motor only when the
steering wheel is being turned, it consumes
less energy than the traditional hydraulic
power steering system (HPS), which is driven
by a hydraulic pump that is constantly in
operation when an engine is on. This can result
in a fuel efficiency improvement of about 3%5%.
Another major advantage is the elimination of
a belt-driven engine accessory, and several
high-pressure hydraulic hoses between the
hydraulic pump, mounted on the engine, and
the steering gear, mounted on the chassis. This
greatly simplifies manufacturing and

Replacing HPSs with EPSs, therefore, would

increase fuel economy and significantly reduce
CO2 emissions thus making it environment
friendly .

BIBLIOGRAPHY :1.Automotive Suspension & Steering System

2.Modern Electric Vehicle Technology by