ZF Active Steering

for Mid-size and Luxury Cars

Steering the right way.
ZF Active Steering for increased
ride comfort and active safety.
Modern car manufacturing with
its ongoing development makes
very high demands on both the
overall concept and on systems
and single components of the
vehicle. ZF Lenksysteme GmbH, a
joint venture of Robert Bosch
GmbH and ZF Friedrichshafen
AG, equips renowned vehicle
manufacturers with both high-
quality single components and
complete steering systems. Early
cooperation by Simultaneous
Engineering offers the advan-
tage that our single components
or systems can be matched to
new vehicle concepts in a way
that saves time and costs.
The ZF Active Steering allows
driver-independent steering in-
tervention at the front axle
2 Steering the right way.
without having to separate the
mechanical coupling between
steering wheel and front axle.
The system basically consists of a
rack and pinion hydraulic
steering gear, a planetary gear
set, an electric motor, some
sensors and an electronic control
unit.
The additional degree of free-
dom permits continuous and
situation-dependent variation of
the steering ratio. Thus, comfort,
steering effort required and ease
of handling are optimized.
So, depending on the driving
situation, the steering angle
effective at the road wheels, is
larger or smaller than adjusted at
the steering wheel by the driver.
At low-speed driving in city
traffic, when much steering work
is necessary, the use of the
electric motor provides for a
smaller number of steering
wheel turns with the same effort
required. At high speeds,
however, the driver no longer
needs to fear that he or she will
lose control of the vehicle as a
result of a steering motion he or
she inadvertently carries out too
intensely. If the electric motor is
static, there is a direct connection
between the steering wheel and
the road wheels as is the case on
conventional steering gears.
Also, steering interventions are
possible to improve vehicle
stabilization.
The ZF Active Steering is
continuously monitored by a
complex safety logic. If the
system has to be deactivated, the
vehicle remains fully steerable
with a constant ratio and full
hydraulic assistance.

The ZF Active Steering is a first

step to the steer by wire
function; so fundamental steer
by wire functions can definitely
be implemented at this early
stage, also with regard to the
capability of integration into
a network and signal pro-
cessing. In the short and
medium term, the ZF
Active Steering will gain
widespread acceptance.

Installation schematic of a
ZF Active Steering with ECU,
steering pump with ECO,
oil reservoir, steering column
as well as pressure, suction and
return lines

Steering the right way. 3

System Configuration

10

11

12
2
3
9 4
6
7

Schematic representation of 1 ZF Servotronic 2 (basic unit) 8 Pinion angle sensor

a ZF Active Steering based on
ZF Servotronic 2, type 7882
2 Servotronic 2 rotary valve
3 Electric motor
4 Superposition gear system
5 Electronic control unit
6 Motor angle sensor
7 Electromagnetic locking unit
9 Steering pump with ECO
10 Oil reservoir with fine filter
11 Hoses, anti-vibration hose
12 Cables to power supply, CAN,
ignition, vehicle sensors

4 System Configuration
 Steering
wheel angle
Perfectly matched.
2 4
Two aspects are decisive for the
effectiveness of the ZF Active
Steering: 3
On the one hand, it is of course M +
the high quality of the central
components from ZF Lenksyste- Motor angle
me. But, at the same time, it is (superposition angle)
also their excellent matching Pinion angle
with quite a number of external 1
influencing factors. Thus, this
active steering system can
flexibly adapt to any technical
environment and any driving
situation.

The basic steering gear used for

the active steering system is the
ZF Servotronic 2 which already
includes many comfort functions.
(For construction and function
see separate brochure "ZF Servo-
tronic 2 for Passenger Cars and
Light Commercial Vehicles"). The
electronically controlled speed-
sensitive rack and pinion hydraul-
ic steering gear requires only
minimal effort in static steering
and at low vehicle speeds, e.g. in
parking maneuvers. At higher
speeds, the effort at the steering
wheel increases and the driver
has an especially good feel of the
road and can steer the vehicle
precisely and with directional sta-
bility.
Pinion angle = steering wheel angle + motor angle
The special feature of the
ZF Active Steering is the super-
position gear system (4) with two
input shafts and one output shaft
which is integrated between the
Servotronic 2 rotary valve (2) and
the basic unit (1). This gear
system transmits to the pinion
both the steering torque input,
which comes from the steering
wheel via the steering column
and the Servotronic 2 rotary
valve, and the additional motor
angle (superposition angle) gen-
erated by the electric motor (3).
This means that using the super-
position gear system a steering
angle can be generated by both
the driver and the electric motor
– independently of each other.
The motor angle sensor (6) and
the pinion angle sensor (8) supply
the electronic control unit (5)
with signals for controlling and
checking the status of the
differential angle unit.

ZF Servotronic® is a registered Principle diagram of the

trademark of ZF ZF Active Steering, type 7882

System Configuration 5
 Differential Angle Unit

Superior interaction of mechani-

2 cal components, electrics and
electronics.
7
The differential angle unit is at
the heart of the ZF Active
5 Steering. By generating an addi-
tional motor angle it produces a
kinematic superposition of the
4 steering wheel angle. With its
main subassemblies electric
3 motor (3) and superposition gear
system, this unit is able to
implement the assistance func-
6 tions demanded by the vehicle
electronics – in split seconds
and in accordance with the
1 requirements of the situation.
The traditional steering feel is
not adversely affected by this.

The electric motor is rigidly

11 connected with the worm (4)
which meshes free of play with
the worm gear (8). The direction
8 of rotation, the speed and the
duration of the motor movement
are monitored by an attached
9 motor angle sensor (6).

The superposition gear system is

10 constructed on the principle of a
planetary gear set. It basically
consists of the main components
worm gear (8), two planet
carriers (5), three stepped planet
gears (9) and, as a result of
the fixed screw connection, it
forms a compact gear system.

Representation of a differential 1 Rack 7 Electromagnetic locking unit

angle unit for the ZF Active 2 Servotronic 2 rotary valve 8 Worm gear
Steering, type 7882, with rack 3 Electric motor 9 Stepped planet gear
and Servotronic 2 rotary valve 4 Worm 10 Pinion
5 Planet carrier 11 Sun gear (shaft)
6 Motor angle sensor

6 Differential Angle Unit

 The self-locking action of the
worm drive ensures that rotation
of the worm can exclusively be
effected by the electric motor.
The stepped planet gears Also, the redundant design of
establish the mechanical connec- the safety system includes an
tion between the upper sun gear electromagnetic locking unit (7).
(11, shaft of the Servotronic 2
rotary valve) and the lower sun
gear. The lower sun gear and the
pinion (10) are of an integral
design. This ensures straight
through drive from the
Servotronic 2 rotary valve (2) to 4
the teeth of the rack (1) – and
also in the reverse direction.
3
When a worm gear movement is
generated by the electric motor,
the stepped planet gears orbit
the two sun gears. Due to the
difference in the number of
teeth of the stepped planet
gears, a relative rotation of the 7
sun gears with respect to each
other results. The movements of
the steering wheel and the worm
8
are combined at the lower sun
gear and transmitted to the rack 5
via the pinion. As a result of the
displacement of the rack, there
results an additional effective 11
steering angle. When worm gear
and upper sun gear move in the
same direction, that angle is 9
smaller (negative) and when they
rotate in opposite directions, it is
larger (positive) than would be
determined by the basic ratio.

Section through the superposi-

tion gear system with electric
motor

Differential Angle Unit 7

System Control

Intelligent and highly dynamic.

The electronic control unit devel-

oped for the ZF Active Steering
establishes the connection
between the electrical system of
the vehicle, the vehicle sensors as
well as the steering system
sensors and the differential angle
unit. All the components re-
quired for the control of the ZF
Active Steering are installed on a
multilayer board. The control
unit is designed for operation at
ambient temperatures of -40°C
to +85°C.

The main components of the

electronic control unit are two
32-bit high-capacity micropro-
cessors. These evaluate the
signals of the connected vehicle
and steering system sensors and
calculate the control outputs for
the differential angle unit. Via
the power output stages, which
are also integrated into the ECU,
the electric motor, the electro-
magnetic locking unit, the ECO
valve of the steering pump and
the Servotronic 2 rotary valve are
controlled.

To meet the high safety require-

ments for the steering system,
the electronic control unit moni-
tors all connected components
for their correct function state.
Additionally, the two micro-

Electronic control unit, Right-hand figure:

type 7882 Principle diagram of the signal
flow of a vehicle control concept
to suit the ZF Active Steering

8 System Control
processors monitor their func-
tions mutually. If errors are
detected, suitable actions to
counteract these are initiated
immediately.
at the end of the assembly line,
the functions of the ZF Active
Steering to the requirements of
the vehicle.

The program memory of the ECU

uses flash technology. This allows
the programming of the whole
software by means of the central
plug. The high flexibility en-
sured by this makes it pos-
sible to perfectly adapt,

Vehicle control concept

monitoring and
safety functions ESP
brake assistance
Steering functions
wheel brake stabilizing ESP
angle functions brake
actuator
steering stabilizing
actuators
control
functions

communication interface
Vehicle
Active
actuator
steering assistance Steering
control
functions actuator

monitoring and
safety functions

ZF Active Steering

hardware-related Servotronic ECO

functions control control

Vehicle state variables

System Control 9
 Steering Assistance and
Stabilizing Functions

With the ZF Active Steering,
ZF Lenksysteme makes the first
production-level active steering
system which is capable of
implementing both kinematic
steering assistance functions and
driving stabilizing functions. The
steering assistance functions that
can be defined by ZF Lenk-
systeme can individually be para-
meterized and adapted to the
vehicle selected by the vehicle
manufacturer. Defining the driv-
ing stabilizing functions – and
assuming responsibility for these
– is the vehicle manufacturer's
duty. Further functions, such as
compensation of disturbance
variables and parking-maneuver
assistance, are possible in the
future.
Beyond being a classic steering
aid, the ZF Active Steering
provides a variable, for example
speed-sensitive, steering ratio. At
slow speed, a low steering ratio
makes parking maneuvers and
negotiating sharp turns easier.
The car appears more direct,
more active and easier to handle.
At high speeds, the electric
motor intervenes in a direction

Steering wheel angle

(e.g. 170°)

same direction opposite direc-

Motor angle neutral
of rotation tion of rotation
dF dF dF

Front wheel angle

Steering ratio

iv max indirect

Basic mechanical
ratio

iv min
direct
0
0 60 Vehicle speed [km/h]

Basic diagram of the

speed-sensitive steering ratio of
the ZF Active Steering

10 Steering Assistance and Stabilizing Functions

which is opposite to the move-
ment of the steering wheel, thus
slightly reducing the steering
motion. The steering system
becomes more indirect, the car
more stabilized and driving safer.
The required data is collected by
sensors approximately 100 times
per second. The ECU decides if
and by what amount the steering
angle has to be altered.
the vehicle manufacturers' goals
and support these. At this early
stage, there is within the auto-
motive industry, the vision of a
completely integrated chassis
management. An overriding
electronic control unit will iden-
tify critical driving conditions and
activate the corresponding sub-
systems such as ESP, Active
Steering or ABS in order to make
the best possible contribution to
safe vehicle handling. This is one
of the primary goals in the
further development of ZF Active
Steering Systems.

Another comfort feature is the

steering lead. It allows rapid
steering system response to the
steering command by adding an
extra angle of lead, depending
on the steering velocity input by
the driver.

The capability of system inte-

gration into a network, which
characterizes the ZF Active
Steering, leads to an interesting
advantage of this steering sys-
tem: the assistance of the ESP
function. Thus, vehicle dynamic c.g.
systems will be able to influence
the vehicle not only by braking
interventions alone, as happens
currently, but also by the steering
system. Advantage: the interven-
tion in the steering gear is very
fast and hardly noticeable to the
driver.

Like any product developed by ZF

Lenksysteme, the Active Steering,
too, must be in agreement with Braking forces Lateral forces

c.g. = Vehicle center of gravity

Basic diagram illustrating the

generation of a yaw torque and
its compensation

Steering Assistance and Stabilizing Functions 11


ZF Lenksysteme GmbH
Richard-Bullinger-Strasse 77
D-73527 Schwäbisch Gmünd
Germany
Phone: +49 (0)71 71 / 31-0
Telefax: +49 (0)71 71 / 31-32 22
www.zf-lenksysteme.com
A Joint Venture of
Robert Bosch GmbH and
ZF Friedrichshafen AG
ZFLS 7882 P KB 8/03 e · Printed on paper bleached without use of chlorine
ZF Lenksysteme GmbH:
the systems partner
ZF Lenksysteme GmbH is one of
the largest independent manu-
facturers of power steering
systems for passenger cars and
commercial vehicles. Renowned
automotive manufacturers from
all over the world value us as a
creative and efficient systems
partner for the development of
new and innovative solutions.
As a joint venture of Robert
Bosch GmbH and ZF Friedrichs-
hafen AG, ZF Lenksysteme GmbH
offers its customers a unique
source of expertise when it
comes to integrating a wide
range of top technologies in
modules, system modules or
entire chassis systems.
The benefits for the manufac-
turer are clear to see: even
shorter development times and
optimized production processes
– with quality standards which
just get better and better.
Technical modifications reserved.
[Steering the right way]