Comprehensive Management of Water Ingress in the Torque Overlay Steering System for Enhanced Reliability in Smart Trucks

<div>The reliability and performance of steering systems in commercial vehicles are paramount, given their direct impact on reducing hazardous driving and improving operational efficiency. The torque overlay system is designed to enhance driver control, feedback, and reduce driver fatigue. However, vulnerabilities such as water ingress under certain environmental conditions have raised significant reliability requirements. This article discusses the systematic investigation into how radial bearing sideloading led to the input shaft seal failing to contact the input shaft. Water was allowed a path to enter the TOS module, affecting the electronic sensor, and faulting out the ADAS functionality. Improvement to the bearing support and sealing design culminated to an enhanced TOS module package able to withstand testing procedures that mimic the environmental and use case situation which caused the ingress.</div>