Electric power steering system having fail-safe control module operation

1. An electric power steering system comprising:

a steering assist assembly;

a motor assembly that actuates said steering assist assembly;

a control module that provides steering assist commands to said motor assembly, said control module including a circuit board having a first portion having at least one protected circuit thereon and a second portion that includes at least one exposed sensor circuit that receives signals from at least one sensor subsystem; and

a potting material coating only said first portion of said circuit board;

the at least one exposed sensor circuit being unprotected from exposure to contamination;

the at least one exposed sensor circuit connected to the at least one protected circuit so as to provide, together with the protected circuit, a primary function of the electric power steering system;

the at least one exposed sensor circuit connected to the at least one protected circuit and configured to operate, together with the protected circuit, in a fail-safe mode following impairment of the at least one exposed sensor circuit;

the fail-safe mode characterized in that, following impairment of the at least one exposed sensor circuit, the at least one exposed sensor circuit and the at least one protected circuit continue to provide said primary function and a warning is issued indicative of the at least one exposed sensor circuit being exposed to contamination.

2. The electric power steering system of claim 1 , including a housing, said control module contained within said housing, said housing being sealed to prevent environmental contamination within said housing.

3. The electric power steering system of claim 1 , wherein said at least one sensor subsystem includes a sensor that measures handwheel torque.

4. The electric power steering system of claim 3 , wherein said at least one sensor subsystem includes a sensor that measures vehicle speed.

5. The electric power steering system of claim 1 , wherein the second portion includes at least one circuit that receives signals from at least one vehicle system.

6. The electric power steering system of claim 1 , wherein the control module initiates a safe operation prohibiting said motor assembly from applying force upon receiving a signal from said at least one exposed sensor circuit.

7. The electric power steering system of claim 1 , wherein the control module monitors said at least one sensor subsystem to detect environmental contamination.

8. The electric power steering system of claim 1 , wherein said primary function comprises executing one or more steering system diagnostic routines.

9. The electric power steering system of claim 1 , wherein said fail-safe mode comprises inhibiting an application of a force by the motor assembly to actuate the steering assist assembly.

10. An electric power steering system for a vehicle, the system comprising:

a steering assist assembly;

a motor assembly that actuates the steering assist assembly;

a control module that provides steering assist commands to the motor assembly, the control module including a circuit board having a first portion having at least one protected circuit thereon and a second portion that includes a first exposed sensor circuit that receives signals from a first sensor subsystem and a second exposed sensor circuit that receives signals from a second sensor subsystem; and

a potting material coating only the first portion of the circuit board;

the first and second exposed sensor circuits being unprotected from exposure to contamination;

the first and second exposed sensor circuits connected to the at least one protected circuit so as to provide, together with the protected circuit, a primary function of the electric power steering system;

the first and second exposed sensor circuits connected to the at least one protected circuit and configured to operate, together with the protected circuit, in a safe mode following impairment of at least one of the first and second exposed sensor circuits;

the safe mode characterized in that, following impairment of at least one of the first and second exposed sensor circuits:

the impaired first and/or second exposed sensor circuit sends an abnormal condition signal to the control module;

the control module, based on receiving the abnormal condition signal, impairs the performance of the steering assist assembly or disables the steering assist assembly; and

a warning is issued to a driver of the vehicle to indicate that the steering assist assembly of the vehicle is impaired or disabled.

11. The electric power steering system of claim 10 , wherein the control module is configured such that it cannot reactivate the steering assist assembly until the vehicle and/or the control module is restarted.

12. The electric power steering system of claim 10 , wherein the first sensor subsystem is a torque sensor and the second sensor subsystem is a vehicle velocity sensor, the first exposed sensor circuit receiving a torque signal from the torque sensor and the second exposed sensor circuit receiving a vehicle velocity signal from the vehicle velocity sensor.

13. The electric power steering system of claim 12 , further comprising a third exposed sensor circuit that receives signals from a third sensor subsystem, the third sensor subsystem being a rotational position sensor sending a pinion gear angle signal.

14. The electric power steering system of claim 13 , further comprising a fourth exposed sensor circuit that receives signals form a fourth sensor subsystem, the fourth sensor subsystem being an acceleration sensor sending a yaw angle velocity value signal.