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ABS/TCS/ESP TRAINING GUIDE ABS/TCS/ESP TRAINING GUIDE Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE CONTENTS HYDRAULIC FUNDAMENTALS -1.1 PASCAL’S LAW 1.2 FORCE 1.3 PRESSURE 1.4 PRESSURE ON A CONFINED FLUID 1.5 FORCE MULTIPLICATION -1.6 PISTON TRAVEL 1.7 HYDRAULIC SYSTEM 1.8 THE FLUID RESERVOIR -1.9 THE PUMP -1.10 VALVE MECHANISM 1.11 AN ACTUATING MECHANISM - ABS GENERAL -2.1 A BRIEF HISTORY OF ABS -2.2 ADVANTAGES OF ABS 2.3 ABS TYPES 2.4 ABSCM 2.5 TYPICAL ABS CONTROL CYCLES 2.6 PHYSICAL PRINCIPLES -2.7 SELECT LOW CONTROL FOR THE REAR WHEEL -2.8 ABS GENERAL CONSTRUCTION 2.9 WHEEL SPEED SENSOR - 2.10 FEATURE OF G-SENSOR Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE 2.11 G SENSOR 2.12 SYSTEM LINE-UP - LUCAS (F2, WITHOUT EBD) 3.1 LUCAS ABS CONTENTS 3.2 LUCAS ABS HCU & ABSCM -3.3 LUCAS ABS CONSTITUTION 3.4 SPECIFICATIONS 3.5 LOCATION -3.6 COMPONENTS -3.7 LUCAS ABS OPERATION -3.8 LUCAS ABS HYDRAULIC CIRCUIT 3.9 LUCAS ABS OPERATION -3.10 CONNECTORS 3.11 SRI LAMP FLASH CODE -3.12 INPUTS / OUTPUTS -3.13 LUCAS ABS TROUBLESHOOTING 3.14 LUCAS ABS WIRING DIAGRAM (KEY OFF) 3.15 LUCAS ABS WIRING DIAGRAM (KEY ON) -3.16 LUCAS ABS WIRING DIAGRAM 3.17 LUCAS ABS WIRING DIAGRAM (ABS FAILURE) -3.18 LUCAS ABS WIRING DIAGRAM - INTEGRATED ABS/TCS -4 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE 4.1 HYDRAULIC CONTROL UNIT(HCU) -4.2 HCU OPEATION 4.3 EBD OPERATION 4.4 ACTIVE WARNING LAMP MODULE MGH-10 (Mando, with EBD) -5.1 ABS NEW ACCENT(LC) -5.2 PRACTICE SHEET -5.3 ABS (SANTA FE) -5.4 BTCS (SANTA FE) MGH-20 (Mando, with EBD) -6.1 ABS (Hyundai coupe: GK) 6.2 BTCS Matrix(FC) -6.3 FTCS (Hyundai coupe: GK) - MK-20 (TEVES) -7.1 ABS (EF SONATA, XG) -7.2 FTCS (EF SONATA, XG) BOSCH 5.3 (with EBD) 8.1 ABS 5.3 (NEW EF SONATA) -8.2 ABD 5.3 (BTCS - NEW EF SONATA) 8.3 ASR 5.3 (FTCS - NEW EF SONATA) - NISSHINBO ABS (with EBD) -5 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE 9.1 NT20S2 (TRAJET) -9.2 NT20Si (TERRACAN) 9.3 NTY3 (ATOS) - 10 ESP (Electronic Stability Program, TEVES MK25) -10.1 MK25(CENTENNIAL) - Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE HYDRAULIC FUNDAMENTALS Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE HYDRAULIC FUNDAMENTALS 1.1 PASCAL’S LAW In the early seventeenth century, Pascal, a French scientist, discovered the hydraulic lever Through controlled laboratory experiments, he proved that force and motion could be transferred by means of a confined liquid Further experimentation with weights and pistons of varying size, Pascal also found that mechanical advantage or force multiplication could be obtained in a hydraulic pressure system, and that the relationships between force and distance were exactly the same as with a mechanical lever From the laboratory data that Pascal collected, he formulated Pascal’s Law, which states : “Pressure on a confined fluid is transmitted equally in all directions and acts with equal force on equal areas.” This law is a little complex to completely understand as it stands right now The following illustrations and explanations break down each concept and discuss them thoroughly enough for easy understanding and retention 1.2 FORCE A simplified definition of the term force is : the push or pull exerted on an object There are two major kinds of forces : friction and gravity The force of gravity is nothing more than the mass, or weight of an object In other words, if a steel block weighing 100 kg is sitting on the floor, then it is exerting a downward force of 100 kg on the floor The force of friction is present when two objects attempt to move against one another If the same 100 kg block were slid across the floor, there is a dragging feeling involved This feeling is the force of friction between the block and the floor When concerned with hydraulic valves, a third force is also involved This force is called spring force Spring force is the force a spring produces when it is compressed or stretched The common unit used to measure this or any force is the kilogram (kg), or a division of the kilogram such as the gram (g) 1.3 PRESSURE Pressure is nothing more than force (kg) divided by area (m 2), or force per unit area Given the same 100kg block used above and an area of 10m on the floor ; the pressure exerted by the block is : 100kg/10m2 or 10kg per square meter 1.4 PRESSURE ON A CONFINED FLUID Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE Pressure is exerted on a confined fluid by applying a force to some given area in contact with the fluid A good example of this would be if a cylinder is filled with a fluid, and a piston is closely fitted to the cylinder wall having a force applied to it, thus, pressure will be developed in the fluid Of course, no pressure will be created if the fluid is not confined It will simply “leak” past the piston There must be a resistance to flow in order to create pressure Piston sealing, therefore, is extremely important in hydraulic operation The force exerted is downward (gravity) ; although, the principle remains the same no matter which direction is taken The pressure created in the fluid is equal to the force applied ; divided by the piston area If the force is 100 kg, and the piston area is 10m 2, then pressure created equals 10kg/m = 100kg/10m2 Another interpretation of Pascal’s Law is that : “Pressure on a confined fluid is transmitted undiminished in all directions.” Regardless of container shape or size, the pressure will be maintained throughout, as long as the fluid is confined In other words, the pressure in the fluid is the same everywhere The pressure at the top near the piston is exactly same as it is at the bottom of the container, thus, the pressure at the sides of the container is exactly the same as at top and bottom 1.5 FORCE MULTIPLICATION Going back to the previous figure and using the 10kg/m created in the illustration, a force of 1,000kg can be moved with another force of only 100kg The secret of force multiplication in hydraulic systems is the total fluid contact area employed The figure shows an area that is ten times larger than the original area The pressure created with the smaller 100kg input is 10kg/m The concept “Pressure is the same everywhere”, means that the pressure underneath the larger piston is also 10 kg/m2 Reverting back to the formula used before : Pressure = Force/Area or P = F/A, and by means of simple algebra, the output force may be found Example : 10kg/m2 = F(kg) / 100m2 This concept is extremely important as it is used in the actual design and operation of all shift valves and limiting valves in the valve body of the transaxle It is nothing more than using a difference of area to create a difference in pressure in order to move an object 1.6 PISTON TRAVEL Returning to the small and large piston area discussion The relationship with a mechanical lever is the same, only with a lever it’s a weight-to-distance output rather a pressure-to-area output Referring to following figure, using the same forces and areas as in the previous example ; it is shown that the smaller piston has to move ten times the distance required to move the larger piston 1m Therefore, for every meter the larger piston moves, the smaller one moves ten meters This principle is true in other instances, also A common garage floor jack is a good example To raise a car weighing 1,000kg, an effort of only 25kg may be required But for every meter the car moves upward, the jack handle moves many times that distance downward 10 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE In ESP control (pressure increase) The on/off booster builds up a pressure of approximately 10 bar in order to enable the ESP pump to suck brake fluid at low temperatures In this position, the inlet valve is driven in a pulsed cycle The TCS valve is closed The outlet valve remains closed The electrically operated shuttle valve is opened The hydraulic pressure is led to the wheel brakes which are to be applied for a brief period of time 10.7 Location of ESP components 227 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE 10.8 Inputs and outputs Inputs Outputs WSS (FL) Motor pump WSS (FR) Solenoid valves WSS (RL) WSS (RR) Steering angle sensor Sensor cluster Pressure sensor 2EA E S P C M ABS,EBD W/L TCS/ESP W/L TCS/ESP F/L CAN communication with ETCM Brake switch ESP / TCS OFF S/W 10.9 Inputs Active wheel speed sensor (Magnetoresistive sensor) Design of the active wheel sensor resistors which can be changed magnetically evaluation electronics V 228 voltage supply Chonan Technical Service Training Center booster/comparator ABS/TCS/ESP TRAINING GUIDE a Function of the active sensor system When moving, the sensor gear touches two of the resistors, disrupting the measuring bridge, and we generate a sinusoidal signal The evaluation electronics converts the sinusoidal signal into a square wave signal The signal can be processed directly by the ABS control unit Generated output current from the sensor is 7mA or 14mA So in order to check the sensor function, the output current needs to be check If the current measurement is not available, the output voltage waveform can be checked 13.6V 12V 13.3V [When the ignition key on] [While driving] b Checking routing for the active wheel sensor The wheel sensors are constantly checked electrically by the control unit In addition, the sensor signal is checked while the vehicle is running If there is a malfunction or a nonplausible physically possible signal, the ABS is switched off and the ABS warning lamp is switched on c Specification • Type: MR(Magnetic Resistance) type • Supplying power: DC 12V • Output current: IL = 7mA, IH = 14mA • Air gap: cannot be measured and adjusted: 229 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE  Front: 0.0945~1.245 mm, Rear: 0.045~0.9545 mm • Teeth of tone wheel: 49 Supporting magnet d Active sensor elements The sensor element consists of the actual sensor element itself and a small supporting magnet Sensor element f Comparison between the passive wheel sensor and the active wheel sensor Item Passive sensor Active sensor Sensor Size Larger Smaller (possibly smaller by 40~50%) One Chip Impossible Good Mass production Medium Good Zero Speed Cannot be detected at low speed ( 3km/h or less) Nearly KPH (Intelligent Type) Temp -40 ~ +125 ℃ -40 ~ +150 ℃ Air-gap Sensitivity Sensitive (Vout∝ 1/(gap)2) Max.: 1.3mm Dull (frequency change) Max.: 3.0mm Anti-noise Poor Good Sensor cluster (Yaw rate sensor + Lateral acceleration sensor) The lateral acceleration sensor and the yaw rate sensor are important components of the ESP The cluster links these sensors to an on-board computer unit and to a CAN interface, incased in a sturdy housing, that is mounted on the chassis Its modular concept allows the integration of further sensor functions 230 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE a Function of yaw rate sensor - Application: Detect the yawing motion of the vehicle, triggering an ESP control intervention if the yaw velocity reaches round about 4°/s (= full circle in 90s) - Installation position: • Tuning forks vertical • Required accuracy of position: max ±3° tolerance to maintain full comfort • Failure to maintain the specified installation position will result in asymmetrical control 11.3 MHz - Design and function The yaw rate sensor relies on the action of microscopic tuning forks The plane in which these forks vibrate shifts when the car turns about its vertical axis This shift is evaluated electronically - Failsafe A faulty yaw rate sensor produces an output signal of 0V 11 MHz - Specification • Supply voltage : 4.75 ~ 5.25V • Zero position : 2.5V • Operation : 27mV (°/s) b Function of lateral acceleration sensor - Application Sense the lateral acceleration of the vehicle 231 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE - Design In the interior of the sensor, a small mass element is attached to a movable lever arm which is deflected by lateral acceleration - Function • Between two electrically charged stationary plates having the same polarity, an electrically charged silicon element having the opposite polarity is attached to the end of a cantilever arm • Between these three plates, two electric fields are generated by the capacitances C1 and C2 • The capacitances C1 and C2 change in response to lateral acceleration This change can be used to calculate the direction and amount of lateral acceleration acting on the vehicle • The same sensor can also be used as longitudinal acceleration sensor if it is installed in the direction of travel • For 0g lateral acceleration, the sensor produces an output signal with a voltage of 2.5V - Other • The signal of the lateral acceleration sensor alone cannot trigger an ESP intervention The sensor is mainly used for estimating the coefficient of friction • The installation location of the lateral acceleration sensor is more critical than that of the yaw rate sensor(lever arm) • The installation location may not be changed after repairs c Hi-scan data 232 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE [Current data] [CAN communication signal] [Yaw rate while turning left] [Yaw rate while turning right] [Lateral G acceleration to the left] [Lateral G acceleration to the right] 233 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE [When the sensor is open] [DTC when the sensor is open] Steering angle sensor Application - Location: Inside steering wheel - Calculate the steering amount and direction - Input Signals (ST 1, ST 2, ST N) - ST N detects the neutral position of steering wheel Specification STN - Sensor type : Photo interrupt type - Sensor output type : Open Collector Type - Output pulse quantity :45pulse (Pulse cycle 8°) - Duty ratio : 50±10% - Phase difference of outputs : 2.0 ±0.6° - Supply voltage :IGN1(8~16V) - Output voltage :1.3≤VOL ≤2.0V, 3.3≤VOH ≤4.0V - Maximum rotational velocity : 1,500°/s Hi-can data 234 Chonan Technical Service Training Center ST1 ST1 ST2 STN [Steering sensor output, ST1/ST2] [Steering sensor output, ST1/STN ABS/TCS/ESP TRAINING GUIDE [When the sensor is open] [Current data when the sensor is open] Application Pressure sensor • Sense the driver’s braking intentions (braking while an ESP intervention is in progress) • Control the precharging pressure Design The sensor consists of two ceramic disks, one of which is stationary and the other movable The distance between these disks changes when pressure is applied Failsafe Guaranteed by redundant installation Installation 235 are mounted Chonan Technical Center The sensors on theService TMC Training (primary and secondary circuits) ABS/TCS/ESP TRAINING GUIDE Function • The pressure sensors operate on the principle of changing capacitance • The distance (s) between the disks and, thus, the capacitance changes when pressure is applied to the movable disk by a braking intervention • The characteristic of the sensor is linearized • The fluid displacement of the sensor is negligible • Max measurable pressure: 170 bar s s1 Output](V) Specification - Supply voltage : 4.75 ~ 5.25V - Zero position : 0.5V - Operation : 23mV/bar Upper fault area 5.0 4.75 Sensor 0.5 Sensor zero point 0.25 0.0 lower fault area t 236 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE [Pressure sensor characteristics] [Pressure sensor output signal] ESP switch • The ESP switch deactivates the ESP and TCS functions • The ESP switch is located in the center console of the vehicle The system is generally active after each new start and is only deactivated by actuating the ESP switch • This facilitates - rocking to free the vehicle in deep snow or loose surface material - driving with snow chains - operation of the vehicle on a brake test bench • The ABS function is fully maintained • The system is reactivated by actuating the ESP a second time • With the ESP switch, the ESP system can only be deactivated when the vehicle is stationary or traveling at low speed The system cannot be deactivated while an ESP intervention is in progress 10.10 Outputs Warning lamp control a) EBD warning lamp control The EBD warning lamp is on : - During the initialization phase (3seconds) - In the event of inhibition of EBD functions - Depending on the warning lamp module, when the controller is switched off as long as voltage is applied at the ignition terminal (IG1) 237 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE b) ABS warning lamp control The ABS warning lamp is on : - During the initialization phase (3seconds) - In the event of inhibition of ABS functions (include ECE-ABS mode) - Depending on the warning lamp module, when the controller is switched off as long as voltage is applied at the ignition terminal (IG1) - During diagnostics c) TCS/ESP OFF warning lamp control The TCS/ESP warning lamp is on : - During the initialization phase (3seconds) - In the event of inhibition of TCS/ESP functions - During diagnostics d) TCS/ESP function lamp control The TCS/ESP function lamp is on : - During the initialization phase (3seconds) The TCS/ESP function lamp is blinking : - During TCS/ESP control - At the ESP off mode depending on ESP off switch, ESP control is available and ESP function lamp is blinking only when brake is turned on by driver • The ESP warning lamp lights up briefly when the ignition is turned on and is extinguished as soon as the peripherals have been checked • During an ESP/TCS control cycle, the ESP function lamp flashes to show the driver that the system is active and that the vehicle is at the limit of its physical capabilities • Detection of the fault in the ESP system causes the ESP warning lamp to light up and remain on The ESP system is then inactive, the ABS function is fully maintained 238 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE 10.11 Failsafe Block diagram [Electronic controller for ABS, TCS and ESP] Safety concept of the ESP control unit In an emergency, it is vital that all ESP components function with absolute reliability For this reason, various safety options must be available which guarantee the function of the system The most important of these safety options are: • self-test of the electronic control unit • peripheral test of the connected assemblies Safety and monitoring system Turning on the ignition activates a self-test of the electronic control unit After staring, all electric connections are monitored continuously 239 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE During the trip, the solenoid valves are checked at regular intervals by means of passive test pulses In addition, all sensor signals are monitored continuously The separation of brake circuits enables the ABS function to be maintained if one brake circuit should fail This means that the driving stability of the vehicle is maintained during critical braking maneuvers For workshop diagnosis, all faults detected are stored in a nonvolatile memory in the ESP control unit for retrieval in the workshop location System monitoring The following items are controlled by the ECU: • 12 valves • Booster (solenoid valve) • ABS pump • ABS/ESP warning lamps The following items are monitored by the ECU: • electronic control unit (include pump and valves) • wheel speed sensors • yaw rate sensor • lateral acceleration sensor • longitudinal acceleration sensor (all-wheel drive vehicle only) • pressure sensor • onboard voltage • CAN bus communication The steering wheel angle sensor monitors itself and signals its state to the electronic control unit DTC Trouble location via the CAN bus C1604 ECU Hardware DTC list C1700 Variant no coding C1200 Wheel speed sensor front left –electrical C1201 Wheel speed sensor front left –extrapolate C1202 Wheel speed sensor front left –other C1203 Wheel speed sensor front right –electrical C1204 Wheel speed sensor front right –extrapolate C1205 Wheel speed sensor front right –other C1206 Wheel speed sensor rear left –electrical C1207 Wheel speed sensor rear left –extrapolate C1208 Wheel speed sensor rear left –other C1209 Wheel speed sensor rear right –electrical C1210 Wheel speed sensor rear right –extrapolate C1211 Wheel speed sensor rear right –other C2112 Valve relay 240 Chonan Technical Service Training Center ABS/TCS/ESP TRAINING GUIDE DTC Trouble location C1235 Pressure sensor (primary) –electrical C1236 Pressure sensor (secondary) –electrical C1237 Pressure sensor –other C1259 Steering wheel sensor –electrical C1260 Steering wheel sensor –signal/other C1282 Yawrate & lateral G sensor –electrical C1283 Yawrate & lateral G sensor –signal/other C1101 Battery Over voltage C1102 Battery Under voltage C1513 Brake lamp switch C2402 Motor C1616 CAN Bus off C1611 CAN timeout EMS C1612 CAN timeout TCU C1503 TCS/ESP Switch C2227 Excessive temperature of brake disk 241 Chonan Technical Service Training Center ... Center ABS/ TCS/ ESP TRAINING GUIDE 13 Chonan Technical Service Training Center ABS/ TCS/ ESP TRAINING GUIDE ABS GENERAL 14 Chonan Technical Service Training Center ABS/ TCS/ ESP TRAINING GUIDE ABS GENERAL... Service Training Center ABS/ TCS/ ESP TRAINING GUIDE 2.1 A BRIEF HISTORY OF ABS ▪ 1952 ABS for aircraft by Dunlop ▪ 1969 Rear-wheel-only ABS by Ford & Kelsey Hayes ▪ 1971 Four-wheel ABS by Chrysler &.. .ABS/ TCS/ ESP TRAINING GUIDE Chonan Technical Service Training Center ABS/ TCS/ ESP TRAINING GUIDE CONTENTS HYDRAULIC FUNDAMENTALS