Bosch automotive electrics and automotive electronics

Bosch Professional Automotive Information Robert Bosch GmbH (Ed.) Bosch Automotive Electrics and Automotive Electronics Systems and Components, Networking and Hybrid Drive 5th Edition Editor: Robert Bosch GmbH Automotive Aftermarket (AA/COM3) Robert Bosch GmbH Plochingen, Germany Published by: © Robert Bosch GmbH, 2007 Postfach 11 29 D-73201 Plochingen Automotive Aftermarket Division, Business Unit Diagnostics Marketing – Test Equipment (AA-DG/MKT) 3rd Edition updated and extended, pub 1999 4th Edition, completely revised and extended, January 2004 5th Edition, completely revised and extended, July 2007 Straight reprint of the 5th edition, published by John Wiley & Sons Inc and Bentley Publishers until 2007 ISBN 978-3-658-01783-5 DOI 10.1007/978-3-658-01784-2 ISBN 978-3-658-01784-2 (eBook) The Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available in the Internet at http://dnb.d-nb.de Library of Congress Control Number: 2013938481 Springer Vieweg © Springer Fachmedien Wiesbaden 1999, 2004, 2007, 2013, 2014 This work is subject to copyright All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed Exempted from this legal reservation are brief excerpts in connection with reviews or scholarly analysis or material supplied specifically for the purpose of being entered and executed on a computer system, for exclusive use by the purchaser of the work Duplication of this publication or parts thereof is permitted only under the provisions of the Copyright Law of the Publisher’s location, in its current version, and permission for use must always be obtained from Springer Permissions for use may be obtained through RightsLink at the Copyright Clearance Center Violations are liable to prosecution under the respective Copyright Law The use of general descriptive names, registered names, trademarks, service marks, etc in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use While the advice and information in this book are believed to be true and accurate at the date of publication, neither the authors nor the editors nor the publisher can accept any legal responsibility for any errors or omissions that may be made The publisher makes no warranty, express or implied, with respect to the material contained herein Printed on acid-free paper Springer Vieweg is a brand of Springer DE Springer DE is part of Springer Science+Business Media www.springer-vieweg.de ▶ Foreword In recent decades, the development of the motor vehicle has been marked by the introduction of electronics At first, electronic systems were used to control the engine (electronic fuel-injection systems), then electronic components entered the domain of driving safety (e.g antilock brake system, ABS) More recently, completely new fields of application have emerged in the areas of driving assistance, infotainment and communication as a result of continuous advancements in semiconductor technology Consequently, the proportion of electrics and electronics in the motor vehicle has continuously increased A typical feature of many of these new systems is that they no longer perform their function as standalone systems but operate in interaction with other systems If the flow of information between these systems is to be maintained, the electronic control units must be networked with each other Various bus systems have been developed for this purpose Networking in the motor vehicle is a topic that receives comprehensive coverage in this book Powerful electronic systems not only require information about operating states, but also data from the vehicle’s surroundings Sensors therefore play an important role in the area of automotive electronics The number of sensors used in the motor vehicle will continue to rise The complexity of the vehicle system is set to increase still further in the near future To guarantee operational reliability in view of this complexity, new methods of electronics development are called for The objective is to create a standardized architecture for the electrical system/electronics that also offers short development times in addition to high reliability for the electronic systems Besides the innovations in the areas of comfort/convenience, safety and infotainment, there is a topic that stands out in view of high fuel prices and demands for cutting CO2 emissions: fuel consumption In the hybrid drive, there is great potential for lowering fuel consumption and reducing exhaust-gas emissions The combination of internal-combustion engine and electric motor enables the use of smaller engines that can be operated in a more economically efficient range Further consumption-cutting measures are start/stop operation and the recuperation of brake energy (recuperative braking) This book addresses the fundamental hybrid concepts The traditional subject areas of automotive electrical systems are the vehicle electrical system, including starter battery, alternator and starter These topics have been revised for the new edition New to this edition is the subject of electrical energy management (EEM), which coordinates the interaction of the alternator, battery and electrical consumers during vehicle operation and controls the entire electrical energy balance The new edition of the “Automotive Electric/Automotive Electronics” technical manual equips the reader with a powerful tool of reference for information about the level of today’s technology in the field of vehicle electrical systems and electronics Many topics are addressed in detail, while others – particularly the electronic systems – are only presented in overview form These topics receive indepth coverage in other books in our series The Editorial Team | Contents ▶ Contents 10 Electrical and electronic systems in the vehicle 10 Overview 13 Motronic-engine management system 168 Electronic components in the vehicle 168 Basic principles of semiconductor technology 172 Passive components 24 Electronic diesel control (EDC) 176 Semiconductor components 32 Lighting technology 186 Manufacture of semiconductor 46 Electronic stability program (ESP) components and circuits 54 Adaptive cruise control (ACC) 62 Occupant-protection systems 196 Control units 196 Operating conditions 70 Basic principles of networking 196 Design 70 Network topology 196 Data processing 74 Network organization 200 Digital modules in the control 76 OSI reference model unit 78 Control mechanisms 204 Control unit software 82 Automotive networking 208 Automotive sensors 82 Cross-system functions 208 Basics and overview 83 Requirements for bus systems 211 Automotive applications 85 Classification of bus systems 214 Details of the sensor market 85 Applications in the vehicle 215 Features of vehicle sensors 87 Coupling of networks 216 Sensor classification 87 Examples of networked vehicles 218 Error types and tolerance 92 Bus systems 219 Reliability 92 CAN bus 222 Main requirements, trends requirements 106 LIN bus 112 MOST bus 122 Bluetooth 132 FlexRay 229 Overview of the physical effects for sensors 231 Overview and selection of sensor technologies 144 Diagnosis interfaces 232 Sensor measuring principles 152 Architecture of electronic systems 232 Position sensors 259 Speed and rpm sensors 152 Overview 271 Acceleration sensors 155 Vehicle system architecture 276 Pressure sensors 279 Force and torque sensors 162 Mechatronics 288 Flowmeters 162 Mechatronic systems and 294 Gas sensors and concentration components sensors 164 Development methods 298 Temperature sensors 166 Outlook 308 Imaging sensors (video) Contents | 310 Sensor types 384 Vehicle electrical systems 310 Engine-speed sensors 384 Electrical energy supply in the 312 Hall phase sensors 313 Speed sensors for transmission control 316 Wheel-speed sensors 320 Micromechanical yaw-rate sensors 323 Piezoelectric “tuning-fork” yaw-rate sensor 324 Micromechanical pressure passenger car 486 Electromagnetic compatibility (EMC) and interference suppression 388 Electrical energy management 486 EMC ranges 390 Two-battery vehicle electrical 487 EMC between different systems system 391 Vehicle electrical systems for commercial vehicles 394 Wiring harnesses 396 Plug-in connections in the vehicle 494 EMC between the vehicle and its surroundings 498 Guarantee of immunity and interference suppression sensors 326 High-pressure sensors 400 Starter batteries 500 Symbols and circuit diagrams 327 Temperature sensors 400 Function and requirements 500 Circuit symbols 328 Accelerator-pedal sensors 402 Design 508 Circuit diagrams 330 Steering-angle sensors 407 Operating principle 519 Designations for electrical devices 332 Position sensors for transmission 411 Battery designs 521 Terminal designations control 418 Battery characteristics 335 Axle sensors 422 Type designations 336 Hot-film air-mass meters 423 Practical and laboratory 339 Piezoelectric knock sensors 340 SMM acceleration sensors battery testing 343 Piezoelectric acceleration sensors 344 iBolt™ force sensor 346 Torque sensor 347 Rain/light sensor Abbreviations Background Information 434 Alternators 52 ABS versions 434 Electrical power generation 53 History of radar in the vehicle 435 Operating principle of the alternator 348 Two-step Lambda oxygen sensors 443 Voltage regulation 352 LSU4 planar wide-band lambda 448 Overvoltage protection oxygen sensor Technical terms 427 Battery maintenance 342 Micromechanical bulk silicon acceleration sensors 524 Index of technical terms 69 Micromechanics 81 Comparison of bus systems 175 Miniaturization 199 Performance of electronic control units 451 Characteristic curves 297 Piezoelectric effect 453 Power losses 383 Greenhouse effect 354 Actuators 453 Alternator circuits 399 History of the alternator 354 Electromechanical actuators 455 Alternator designs 426 History of the battery 359 Fluid-mechanical actuators 360 Electrical machines 462 Starting systems 462 Overview 366 Hybrid drives 462 Starter 366 Drive concepts 472 Other types of starter motor 370 Operating strategies for electric 476 Starting systems hybrid vehicles 376 Recuperative brake system 380 Electrical energy accumulators 481 Design 484 Overview of the types of starters ▶ Authors Electrical and electronic systems in the vehicle Electronic components Dipl.-Ing Bernhard Mencher; Dr rer nat Ulrich Schaefer Dipl.-Ing (BA) Ferdinand Reiter; Dipl.-Ing Andreas Glaser; Control units Dipl.-Ing Walter Gollin; Dipl.-Ing Martin Kaiser; Dipl.-Ing (FH) Klaus Lerchenmüller; Dr rer nat Ulrich Schaefer; Dipl.-Ing Felix Landhäußer; Dipl.-Ing (FH) Gerhard Haaf Dipl.-Ing Doris Boebel, Automotive Lighting Reutlingen GmbH; Sensors Dr.-Ing Michael Hamm, Dr.-Ing Erich Zabler; Automotive Lighting Reutlingen GmbH; Dr rer nat Stefan Finkbeiner; Dipl.-Ing Tilman Spingler, Dr rer nat Wolfgang Welsch; Automotive Lighting Reutlingen GmbH; Dr rer nat Hartmut Kittel; Dr.-Ing Frank Niewels; Dr rer nat Christian Bauer; Dipl.-Ing Thomas Ehret; Dipl.-Ing Günter Noetzel; Dr.-Ing Gero Nenninger; Dr.-Ing Harald Emmerich; Prof Dr.-Ing Peter Knoll; Dipl.-Ing (FH) Gerald Hopf; Dr rer nat Alfred Kuttenberger Dr.-Ing Uwe Konzelmann; Dr rer nat Thomas Wahl; Networking Dr.-Ing Reinhard Neul; Dipl.-Inform Jörn Stuphorn, Dr.-Ing Wolfgang-Michael Müller; Universität Bielefeld; Dr.-Ing Claus Bischoff; Dr Rainer Constapel, Dr Christian Pfahler; DaimlerChrysler AG Sindelfingen; Dipl.-Ing Peter Weiberle; Dipl.-Ing (FH) Stefan Powolny; Dipl.-Ing (FH) Ulrich Papert; Dipl.-Ing Peter Häußermann, Dipl.-Ing Christian Gerhardt; DaimlerChrysler AG, Sindelfingen; Dipl.-Ing Klaus Miekley; Dr rer nat Alexander Leonhardi, Dipl.-Ing Roger Frehoff; DaimlerChrysler AG, Sindelfingen; Dipl.-Ing Martin Mast; Dipl.-Inform Heiko Holtkamp, Dipl.-Ing (FH) Bernhard Bauer; Universität Bielefeld; Dr Michael Harder; Dipl.-Ing (FH) Norbert Löchel Dr.-Ing Klaus Kasten; Dipl.-Ing Peter Brenner, Architecture of electronic systems ZF Lenksysteme GmbH, Schwäbisch Gmünd; Dr phil nat Dieter Kraft; Dipl.-Ing Frank Wolf; Dipl.-Ing Stefan Mischo Dr.-Ing Johann Riegel Mechatronics Dipl.-Ing Hans-Martin Heinkel; Dr.-Ing Klaus-Georg Bürger Actuators Dr.-Ing Rudolf Heinz; Dr.-Ing Robert Schenk Hybrid drives Dipl.-Ing Michael Bildstein; Dipl.-Ing Boyke Richter; Dr rer nat Richard Aumayer; Dr.-Ing Karsten Mann; Dipl.-Ing Tim Fronzek, Toyota Deutschland GmbH; Dipl.-Ing Hans-Peter Wandt, Toyota Deutschland GmbH Vehicle electrical systems Dipl.-Ing Clemens Schmucker; Dipl.-Ing (FH) Hartmut Wanner; Dipl.-Ing (FH) Wolfgang Kircher; Dipl.-Ing (FH) Werner Hofmeister; Dipl.-Ing Andreas Simmel Starter batteries Dipl.-Ing Ingo Koch, VB Autobatterie GmbH & Co KGaA, Hannover; Dipl.-Ing Peter Etzold; Dipl.-Kaufm techn Torben Fingerle Alternators Dipl.-Ing Reinhard Meyer Starting systems Dipl.-Ing Roman Pirsch; Dipl.-Ing Hartmut Wanner Electromagnetic compatibility Dr.-Ing Wolfgang Pfaff and the editorial team in cooperation with the responsible technical departments at Bosch Unless otherwise specified, the above are all employees of Robert Bosch GmbH 10 | Electrical and electronic systems in the vehicle | Overview Electrical and electronic systems in the vehicle The amount of electronics in the vehicle has risen dramatically in recent years and is set to increase yet further in the future Technical developments in semiconductor technology support ever more complex functions with the increasing integration density The functionality of electronic systems in motor vehicles has now surpassed even the capabilities of the Apollo 11 space module that orbited the Moon in 1969 Overview Development of electronic systems Not least in contributing to the success of the vehicle has been the continuous string of innovations which have found their way into vehicles Even as far back as the 1970s, the aim was to make use of new technologies to help in the development of safe, clean and economical cars The pursuit of economic efficiency and cleanliness was closely linked to other customer benefits Electronics in the motor vehicle Dr ive tra in Co mm un ica Ele c tio n V tron oic ic (sp e co voic e n e Au ech trol o outp dio rec f fu ut (ra equ ogni ncti d ip ti o Vid io, C men on) ns e De t tc On o ) -b Ca oard r p co h Na on mp vi e ute r Ne gatio w n (di dis sp pla l Int ay, y te ern he ch et ad- nol an up og d P dis ies C pla y) Dig it Ga al en so g Die line ine m e die sel e ngin anag s n e e wit el co gine : Mo men h nt : e tro t: rol lec ni ele (E tro c c DC nic fue tron ) l in ical ele jec ly c c ti o (ga tron on, ntro lle i s c d La oline ignit mb en ion bo da gin e c o (tu st-pr ontro ), r e l etc boch ssur , arg e c er) on Ele tro c l co tron ntr ic o t On l ran sm -bo iss ard ion -di ag no sis such as driving pleasure This was characterized by the European diesel boom, upon which Bosch had such a considerable influence At the same time, the development of the gasoline engine with gasoline direct injection, which would reduce fuel consumption by comparison with intake-manifold injection, experienced further advancements An improvement in driving safety was achieved with electronic brake-control systems In 1978, the antilock brake system (ABS) was introduced and underwent continual development to such an extent that it is now fitted as standard on every vehicle in Europe It was along this same line of development that the electronic stability program (ESP), in which ABS is integrated, would debut in 1995 The latest developments also take comfort into account These include the hill hold control (HHC) function, for example, which makes it easier to pull away on uphill gradients This function is integrated in ESP Robert Bosch GmbH (ed.), Bosch Automotive Electrics and Automotive Electronics, DOI 10.1007/978-3-658-01784-2_1, © Springer Fachmedien Wiesbaden 2014 UAE0856-1E An t Tra ilock cti br on ak Sa fet Ele -con e sy y ctr trol ste on sy m (A ic s t sta em BS ) bil ity (TC He pro S) ad gra lam p a (E m d S an just P) d c me lea nt Wa Ind sh- L ning ivid wip itro ua e c nic Mo in lised ontr nit ter se ol ori va rv n l i co g sy disp ce Tri ns st la gg um em y eri a ng w bl s fo se syst earines a r atb em g nd elt s f pa ten or a rts Ve sio irb hic Tir le s roll ner ag, e-p ecu -ov an res rity er d su sy bar re mo stem nit s Co ori mf ng ort /co Ad nv ap en ti ien He ve c ce ati ruis Crui ng e se an co d a tro ntr S Po ea ir-co l (A ol we t a nd CC r-w dju iti ) ind s o ow pos tme ning an ition nt w d - m ith su em n Ch as Cen roof ory Pa sis tra dr rki iv ng c -ai Ba ont l lock e d a ck- rol in ss up sys g ist m te an on m t (P ito ark ring tro nic ) bar 508 | Symbols and circuit diagrams | Circuit diagrams Circuit diagrams Circuit diagrams are idealized representations of electrical devices, rendered in the form of symbols Such diagrams also include illustrations and simplified design drawings as needed (Fig 7) A circuit diagram illustrates the relationship between the various devices and shows how they are connected to each other A circuit diagram may be supplemented by tables, graphs, or descriptions Circuit diagrams vary according to the intended application (e.g showing circuit operation) and the selected representation mode A “legible” circuit diagram will meet the following requirements: ▶ The representations must reflect the applicable standards; explanations should be provided for any exceptions ▶ Current paths should be specially arranged so that current flow or mechanical action takes place from left to right and/or from top to bottom Circuit diagrams: breakdown Circuit diagrams for vehicle electrical systems (compliant with EN 61346-1) Classification according to purpose Classification according to type of representation Circuit diagrams which explain the operation Single or multipole representation Arrangement of switch symbols Representation acc to actual position Connected Partially connected Separated Circuit diagrams which explain the connection Mainly showing internal connections Overview circuit diagram Circuit diagram Terminal connection diagram UAS0968-2E In automotive electrical systems, block diagrams are used to provide a quick overview of circuit and device functions They are usually unipolar and also dispense with representations of internal circuitry components The circuit diagrams in their various permutations (as defined by differences in symbol arrangements) provide a detailed diagram of the circuit As they illustrate how the circuit operates, they are suitable for use as a reference for repair operations The terminal diagram (with equipment terminal locations) is used by service facilities in replacing defective electrical equipment and when installing supplementary equipment Depending upon the type of representation, we distinguish between: ▶ Unipolar and multipolar representation and (according to symbol arrangement) ▶ Assembled representation, semi-assembled representation, detached representation, and topographical (positionally Symbols and circuit diagrams | Circuit diagrams | 509 correct) representation One circuit diagram may employ all of the above forms of representation structure, layout and operation of an electrical system, or part of it This format also serves as the initial reference for understanding more detailed circuit diagrams Squares, rectangles and circles together with attendant symbols based on EN 60 617, Section are employed to illustrate the devices Wiring is usually shown in singlepole form Block diagram The block diagram is a simplified representation of a circuit showing only the most significant elements (Fig 8) It is designed to furnish a rapid overview of function, Motronic ECU block diagram Fig A1 ECU B1 Engine-speed sensor B2 Reference-mark 30 G1 B3 Air-mass meter B4 Intake-air M1 50 S1 sensor M D2 temperature sensor B5 Engine-temperature sensor CPU B1 U1 B4 D3 ROM D4 D5 B6 Throttle-valve N1 switch K1 D1 Microprocessor B2 B3 D1 RAM (CPU) U2 D2 Address bus m t U3 D6 D3 User memory N2 (RAM) T1 D4 Program data t memory (ROM) U4 D5 I/O B5 t D6 Data bus U5 N3 B6 D7 Microcomputer Y1 G1 Battery K1 Pump relay U6 M1 Electric fuel-supply S2 D7 A1 pump N1 to N3 Power-output stages S1 Ignition switch S2 Program map selector T1 Ignition coil UMK0052-2Y U1 and U2 Pulse shapers U3 to U6 Analog/digital converters Y1 Fuel injector 510 | Symbols and circuit diagrams | Circuit diagrams Circuit diagram A circuit diagram is the detailed representation of a circuit By clearly depicting individual current paths it also indicates how an electrical circuit operates In the circuit diagram, presentation of individual circuit components and their spatial relationship to each other must not interfere with the clear, logical and legible presentation of circuit operation Figure shows the circuit diagram for a starter, in the form of assembled (composite) and detached (exploded) representations The circuit diagram must contain the following: ▶ Wiring ▶ Device designation (EN 61 346, Section 2) ▶ Connection designation or terminal designation (DIN 72 552) The circuit diagram may also include: ▶ Comprehensive illustrations including internal circuitry, to facilitate testing, trouble-shooting, maintenance and replacement (retrofitting) ▶ Reference codes to assist in finding symbols and installation locations, especially in detached representation diagrams Two different ways of showing the circuit diagram for a Type KB starter motor for parallel operation a 50 30 50b 30f K1 K2 M M1 31 b 30 30 30f K1 Fig a Assembled b Detached K1 K1 50 representation 50b M1 K2 M1 representation K1 K1 Control relay K2 hold-in winding, M K2 pull-in winding M1 Starter motor with series and shunt winding 31 M1 31 UAS1221-1Y K2 Engagement relay, Symbols and circuit diagrams | Circuit diagrams | 511 Circuit representation Circuit diagrams usually use multipolar component connections In accordance with EN 61 346, Section 1, symbols can be represented in the following ways, all of which may be combined within the same circuit diagram Assembled (composite) representation All parts of a device are shown directly next to one another, and mechanical linkage of one part to another is indicated by a double line or broken connecting lines (dashes) This format may be employed to depict simple circuits of relatively limited complexity without unduly hindering clarity (Fig 9a) Ground representation a + A system of symbols defined in EN 61 346, Section can be used to indicate the relationships between the individual components Each separately illustrated device symbol includes the code for the device If it is necessary in the interests of clarity and comprehension, a section of the circuit diagram should be set aside for the complete and assembled representation of devices which have otherwise been shown in the detached form (Fig 9b) Topographical representation This type of representation places the symbol in a position that completely or partly corresponds to its location within the device or component b + 31 c + UAS1222-1Y 10 Detached (exploded) representation Symbols for the elements within electrical devices are shown separately in displays designed to show with maximum clarity the various routes taken by the current No attempt is made to orient the symbols for individual devices and component parts in their actual spatial relationship to each other Priority is assigned to arranging the symbols so that the individual current paths are as clear and free of crossovers as possible Primary purpose: to indicate function and operation of a circuit Ground (earth) symbols For the sake of conceptual simplicity, most vehicles employ a single (hot) conductor layout, relying on the metallic body to conduct the return current Designers resort to insulated return wiring either when restraints prevent using the body for satisfactory ground connections or when voltages in excess of 42 volts are being handled All terminals represented by the ground symbol are mutually connected electrically through the component (housing) or vehicle ground All components with a ground symbol must be mounted on the vehicle ground to Fig 10 a Individual ground symbols b Common ground connection c With common ground point 512 | Symbols and circuit diagrams | Circuit diagrams which they must have a direct electrical connection Figure 10 depicts several options for showing connections to ground ground In high-tension circuits this outer line is frequently combined with the protective conductor (PE), also represented as a broken dotted line Current paths and conductors (wiring) Circuits should be arranged to be clear and easy to follow When possible, individual current paths should indicate a force-transfer direction from left to right and/or from top to bottom, as well as being straight and free of crossovers and changes in direction They should also be parallel to the border of the circuit diagram When a number of conductors run parallel to each other, they are grouped in sets of three with spaces between the groups Interruptions, codes, destination reference For clarity, connecting lines (conductors and lines denoting mechanical linkage) can be interrupted if they would otherwise extend too far within the circuit diagram Only beginning and end of the connecting line are shown The association of these interrupted points must be clearly recognizable The code and / or destination reference may be used for this Lines of demarcation, borders Dot/dash demarcation or border lines are used to separate individual components within a circuit as an indication of functional and/or structural relationships In illustrations of automotive electrical systems, these alternating dots and dashes represent a non-conductive border around a device or circuit component The line will not always correspond with the component housing and does not indicate 11 The codes on associated ends of the open circuit match The following may be used as codes: ▶ Terminal designations (DIN 72 552), Figure 11a ▶ Indication of the function ▶ Identification using alphanumeric symbols The destination reference is shown in parentheses to avoid confusion with the code; it consists of the section number of the target (Fig 11b) Broken-line designation using terminal destinations a b Ignition 30 30 15 –S1 50 Fig 11 15 –S1 –F2 30 30 15 50 (8) (2) 15 –F2 –S16 –S16 –H10 –H10 By terminal designation, e.g terminal 15 b 15 30 With destination reference, e.g in section and 31 31 31 31 UAS1223-1Y a 15 30 Lighting Symbols and circuit diagrams | Circuit diagrams | 513 Section identification The section-identification code along the upper border of the diagram is used for locating circuit sections This designation can be in one of three forms: ▶ Consecutive numbers at equal intervals from left to right (Fig 12a) ▶ Indication of the content of the circuit sections (Fig 12b) ▶ Or a combination of the two (Fig 12c) ▶ Designation codes Devices, parts or symbols are labeled in circuit diagrams with a letter and a serial number as defined in EN 61 346, Section This code is located to the left of or underneath the symbol The prefix to designate the type of device (as specified in the standard) can be omitted as long as this does not lead to ambiguity In nested devices, one device is a component part of another, e.g starter M1 with built-in engagement relay K6 The device identifier is then: – M1 – K6 ▶ Different methods of section identification a Example: Starter – M : 30 Prefix for the type of device Code letter for device Sequence number Terminal designation Example: Terminal 30 Prefix for terminal Terminal code Identification of related symbols in detached views: each individual symbol is shown separately and all symbols for a particular device are assigned a code which is the same as that used for the device itself Connection designations (such as those defined in DIN 72 552) must be placed outside the symbol and, if boundary lines are present, outside these lines if possible … b Power supply Starting system Ignition c Power supply 10 Starting system Ignition UAS1204-1E 12 Device identifier For horizontal current paths: the data associated with the individual symbol is provided beneath the circuit symbol concerned The terminal code is above the connecting line, just outside the symbol proper For vertical current paths: the data applying to the individual symbol are provided to its left The terminal code is just outside the symbol It the type is horizontal, the code is provided next to the connecting line on the symbol’s right; if the type is vertical, it is on the left Fig 12 a With consecutive numbers b With section indication c With a combination of a and b 514 | Symbols and circuit diagrams | Circuit diagrams Terminal diagram The terminal diagram shows the terminal locations of electrical devices It also illustrates the external (and internal as required) connections (lines) at these points Representation Individual electrical devices are illustrated using squares, rectangles, circles, symbols or illustrations, and their locations may correspond to their installed positions The connections are represented by circles, dots, plug connectors, or simply by the connecting line The following conventions govern the methods of representation used in automotive electrical systems: ▶ Assembled, circuit symbols complying with EN 60 617 (Fig 13a) ▶ Assembled, pictorial representation of the device (Fig 13b) ▶ Detached, representation of the device with symbol, terminals with destination references; wiring color codes optional (Fig 14a and Table 2) ▶ Detached, pictorial representation, including terminals with destination references; wiring color codes optional (Fig 14b) Labeling Devices identified in accordance with EN 61 346, Section Terminal connectors and plugged connections are identified with the terminal designations present on the device (Fig 13) Detached views dispense with continuous connecting lines between devices All conductors leaving a device have a destination reference (EN 61 346, Section 2), consisting of the code for the target device and the terminal designation with – if necessary – statement of the wiring color code as specified in DIN 47 002 (Fig 15 and Table 1) ▶ Device identifier – Example: alternator G1 Prefix for the type of device (may be omitted) Code letter and serial number of the device (alternator) ▶ Destination reference – G2 : + / Example: wire from rd alternator G1 to battery G2 Prefix for the type of device (may be omitted) Table Color coding for electrical conductors (in accordance with DIN 47 002) blue gn green bk black Terminal prefix br brown or orange tq turquoise Terminal designation ye yellow pi pink vi violet gr gray rd red wh white 15 H1 D+ 30 B+ With devices U G1 B– 15 30 50a S2 H1 30 50 G2 M1 S2 D+ B+ B– M b Wire color code (red) b 50a G With symbols of the destination terminal Terminal diagram, assembled representation a a serial number (battery) bl 13 Fig 13 Code letter and 50 30 G1 G2 M1 UAS1224-1Y Symbols and circuit diagrams | Circuit diagrams | 515 14 Terminal diagram, detached view A B G1 G U G2 D+ B+ B– + G1 H1 G2:+ G1:B+ S2:30 M1:30 G2 D+ B+ B– + H1 G2:+ G1:B+ S2:30 M1:30 Fig 14 a – – With circuit symbols and destination references b M1 M1 M 30 50 G2:+ S2:50a 30 50 With devices and destination G2:+ S2:50a references G1 Three-phase alternator with voltage regulator G2 Battery H1 Charge indicator H1 H1 S2:15 G1:D+ lamp S2:15 G1:D+ M1 Starter motor S2 Ignition switch XX Device ground on vehicle chassis YY Terminal for ground S2 H1 G2:+ M1:50 15 30 50a H1 G2:+ M1:50 connection :15 Conductor potential, e.g terminal 15 Device identifier (example: alternator) Fig 15 Device representation G U Destination indication D+ B+ B– a sequence number) b Terminal designation on device G1 a Device identifier (code letter and H1/bk G2:+/rd b c d UAS1055-1E 15 15 30 50a UAS1225-1Y S2 c Device to ground d Destination reference (code letter plus serial number/terminal designation/wire color code) 516 | Symbols and circuit diagrams | Circuit diagrams BLU/RED Supplementary data in the block diagrams GRN/BLK 16 GRN/BLU Table Block diagram Bosch has responded to the requirements associated with trouble-shooting on complex, networked systems with a selfdiagnosis function by developing systemspecific circuit diagrams Bosch makes block diagrams for further systems in a great number of motor vehicles available in ESI[tronic] (Electronic Service Information) This provides automotive repair shops with a useful tool for locating faults or wiring retrofit equipment Figure 17 shows the block diagram for a door-locking system The representations in the block diagrams diverge from those in the standard circuit diagrams by relying on US symbols with supplementary legends (Fig 16) These legends include component codes (for instance: “A28” for theft-deterrence system), as shown in Table 3, as well as the color codes for wiring (Table 4) Both tables can be accessed in ESI[tronic] C4 Table C4 Fig 16 Wire color Connector number PIN number (dashes between PINs indicate that all PINs are part of the same plug) GRN / BLU UAS1260-1Y Explanation of component codes Position Description A1865 Electric power-seat system A28 Theft-deterrence system A750 Fuse/relay box F53 Fuse C F70 Fuse A M334 Fuel-supply pump S1178 Warning-buzzer switch Y157 Vacuum actuator Y360 Actuator, door, right front Y361 Actuator, door, left front Y364 Actuator, door, right rear Y365 Actuator, door, left rear Y366 Fuel filler-flap actuator Y367 Actuator, lock, luggage compartment, trunk lid Wire color code chart Position Description BLK Black BLU Blue BRN Brown CLR Transparent DK BLU Dark blue DK GRN Dark green GRN Green GRY Gray LT BLU Light blue LT GRN Light green NCA No Color Assigned ORG Orange PNK Pink PPL Purple RED Red TAN Tan VIO Violet WHT White YEL Yellow Symbols and circuit diagrams | Circuit diagrams | 517 Block diagram for a door-locking system (example) Term 20 Term 15/54 F70 F53 16A 16A RED/WHT BLK/YEL RED/WHT A750 RED/WHT RED/WHT BLK/YEL RED/WHT M334 M RED/WHT UNLOCK BLU Y157 LOCK YEL P A1865 YEL BRN YEL GRN RED/WHT Y360 BLU Y361 GRN A28 YEL BLU UNLOCK Y157 LOCK GRN BRN A28 BRN/BLK YEL YEL Y364 BRN Y157 YEL S1178 Y365 0202 RED/WHT Y366 Y367 UNLOCK YEL YEL YEL Y157 Y157 LOCK YEL BRN/BLK UAS1261-1Y YEL Y157 BRN BRN CONNECTOR BLOCK BRN/BLK 17 518 | Symbols and circuit diagrams | Circuit diagrams System sub-circuits Engine management Starter/charging circuit Heating and air conditioning Radiator fan Left front fender ABS Forward section Vehicle-speed controller/tempomat Engine Power-window unit Bulkhead Central locking system Right front fender Instrument panel 10 Wiper/washing system 11 Headlamps 12 Exterior lighting 13 Power supply 10 Right rear door 14 Ground allocation 11 A-pillars 15 Data line 12 Passenger 16 Shift lock 17 Theft-deterrence system 13 Roof 18 Passive safety and security systems 14 Rear section 19 Electric antenna 20 Alarm system 21 Heated screen/mirror 22 Supplementary safety and security systems Fig 18 Footwell panel or instrument panel Left front door Right front door Left rear door compartment 15 C-pillars 16 B-pillars Table 23 Interior lighting 24 Power-assisted steering 25 Mirror adjuster 26 Soft-top controls 27 Horn 28 Trunk, trunk lid 29 Seat adjustment 30 Electronic damping 31 Cigarette lighter, socket 32 Navigation 33 Transmission 34 Active bodywork components 35 Vibration damping 36 Mobile phone 37 Radio/sound system 38 Immobilizer (drive-away protection) ▶ ▶ Suspension and Drivetrain It is important to be aware of the grounding points, particularly when fitting additional accessories For this reason, ESI[tronic] includes the vehicle-specific location diagram for the grounding points (Fig 18) in addition to the block diagrams 18 Ground points 11 11 12 16 13 16 15 12 15 10 14 UAS1262-1Y Block diagrams are classified according to system circuits, with further divisions by subsystem as indicated (Table 5) Classification of system circuits reflects the standard ESI[tronic] practice as used for other systems, according to which they are assigned to one of four assembly groups: ▶ Engine ▶ Body Symbols and circuit diagrams | Designations for electrical devices | 519 Designations for electrical devices The designation defined in EN 61 346, Section (Table 6) serves as the basis for unambiguous and internationally-recognized labeling conventions for assemblies, components, etc., as represented in circuit diagrams by circuit symbols It appears next to the circuit symbol and consists of a sequence of defined prefixes, letters and numerals ▶ Device identifier Example: Alternator G2, Terminal 15 Prescribed designation code: – G : 15 prefix (may be omitted, as long as this does not cause ambiguity) Code letter for type (here an alternator) from Table Sequence number Terminal (here: Terminal 15) as standard designation or as affixed to the device Identification codes for electrical devices Identification code Type Examples A System, assembly, component group ABS control unit, radio, two-way radios, mobile phone, alarm system, equipment assembly, ignition trigger box, electronic control unit, cruise control B Converter of non-electrical to electrical quantities and vice-versa Reference-mark sensor, pressure switch, fanfare horn, horn, Lambda oxygen sensor, loudspeaker, air-flow sensor, microphone, oil pressure switch, sensors of all types, ignition triggering device C Capacitor All types of capacitors D Binary component, memory On-board computer, digital equipment, integrated circuit, pulse counter, magnetic tape recorder E Various devices and equipment Heating system, air-conditioning system, lamp, headlamp, spark plug, ignition distributor F Protective equipment Initiator trigger (bimetal), reverse-polarity guard, fuse, current protection circuit G Power supply, alternator Battery, alternator, battery charger H Monitor, indicator, signaling device Audible alarm, function lamp, flasher indicators, turn-signal lamp, brake-pad wear indicators, stop lamp, high-beam indicator, alternator-charge indicator, indicator lamp, indicator, oil pressure monitor, optical indicator, signal lamp, buzzer K Relay, contactor Battery relay, turn-signal flasher, flasher relay, engagement relay, starting relay, hazard warning light flasher L Inductance Choke coil, coil, winding M Motor Blower motor, fan motor, pump motor for ABS/TCS/ESP hydraulic modulators, windshield washer/wiper motor, starter motor, servomotor N Regulator, amplifier Regulator (electronic or electromechanical), voltage stabilizer Table 520 | Symbols and circuit diagrams | Designations for electrical devices Table (continued) Identification codes for electrical devices (continued) Identification code Type Examples P Measuring device Ammeter, diagnosis socket, rev counter, pressure display, tachograph, measuring point, test point, speedometer R Resistor Sheathed-element glow plug, flame plug, heating resistor, NTC resistor, PTC resistor, potentiometer, regulating resistor, series resistor S Switches Switches and push-buttons of all kinds, ignition contact breaker T Transformer Ignition coil, ignition transformer U Modulator, converter DC converter V Semiconductor, electron tube Darlington transistor, diode, electron tube, rectifier, semiconductors of all kinds, varicap, transistor, thyristor, Zener diode W Transmission path, conductor, antenna Vehicle antenna, shielding, shielded cable, all types of cable, wiring harness, (common) ground conductor X Terminal, plug, plug-in connection Terminal stud, electrical connections of all types, spark-plug connector, terminal, terminal strip, electric wiring coupling, cable tie, plug, socket, multipoint connector, (multiple) plug connection, distributor connector Y Electrically operated mechanical equipment Permanent magnet, (solenoid) injection valve, solenoid clutch, electromagnetic brake, electric air valves, electric fuel-supply pump, solenoid, electric start valve, transmission control, tractive solenoid, kickdown solenoid valve, headlamp range control, ride-height control valve, switching valve, start valve, door lock, central locking system, auxiliary-air device Z Electric filter Interference suppressor, suppression filter, filter network, clock Symbols and circuit diagrams | Terminal designations | 521 Terminal designations The system of standard (DIN 72 552) terminal designations prescribed for use in automotive applications has been designed to facilitate correct connection of devices and their wiring, with emphasis on repairs and replacement The terminal designations (Table 7) are not wire designations, as devices with differing terminal codes can be connected to the opposite ends of a single wire For this reason, the terminal designations need not be written on the wires In addition to the terminal designations listed, designations according to DIN VDE standards may also be used on electrical machines Multi-pin plug connections large enough to exhaust the range provided by DIN 72 552 are allocated consecutive numbers or letters, avoiding any characters to which the standard has already assigned a specific function DIN 72 552 terminal designations Terminal Definition Terminal Definition Ignition coil, ignition distributor Low voltage 31 b Return line to battery negative or ground via switch or relay (switched negative) 1a 1b Ignition distributor with two isolated electric circuits To ignition contact breaker I To ignition contact breaker II Short-circuit terminal (magneto ignition) Ignition coil, ignition distributor High voltage 4a 4b Ignition distributor with two isolated electric circuits From ignition coil I, terminal From ignition coil II, terminal 15 Switched plus downstream from battery (output from ignition [start] switch) 15 a Output on series resistor to ignition coil and to the starter 17 19 30 30 a 31 1) Glow plug switch Start Preglow Line from battery positive terminal (direct) Battery changeover relay 12/24 V Input from battery II positive Return line from battery negative or ground (direct) Polarity reversal terminal 32/33 possible 31 a 31 c Battery changeover relay 12/24 V Return line to battery II negative Return line to battery I negative 32 33 33 a 33 b 33 f 33 g 33 h 33 L 33 R Electric motors Return line 1) Main terminal 1) Self-parking Shunt field For second reduced-rpm operation For third reduced-rpm operation For fourth reduced-rpm operation Rotation to left (counterclockwise) Rotation to right (clockwise) 45 45 a 45 b 48 49 49 a 49 b 49 c Starter motor Separate starting relay, output Starter: input (primary current) Dual starters, parallel activation Starting relay for pinion-engagement current Starter I output Starter I and II input Starter II output Terminal on starter and start-repeating relay for monitoring the starting process Turn-signal flasher (pulse generator) Input Output Output to second flasher circuit Output to third flasher circuit Table 522 | Symbols and circuit diagrams | Terminal designations DIN 72 552 terminal designations (continued) Terminal Definition Terminal Definition Starter motors Starter control (direct) 58 50 50 a Battery changeover relay Output for starter control Side-marker lamp, tail lamp, license plate lamp, and instrument lamps Tail lamp mode selection on single-axle tractors Trailer gladhand assembly for single-strand tail lamp with fuse in the trailer Adjustable instrument illumination, tail and side-marker lamp Left Right, license-plate lamp 50 b Starter control Parallel operation of two starter motors with sequence control 58 b 58 c 58 d 50 c 50 d Starting relay for sequence control of engagement current in parallel operation of two starter motors Starter I input at starting relay Starter II input at starting relay 50 e 50 f Start-inhibit relay Input Output 50 g 50 h Start repeating relay Input Output (continued) 59 a 59 b 59 c Alternator (magneto alternator) AC voltage output rectifier input Charging armature output Tail lamp armature output Stop lamp armature output 61 Alternator charge indicator 71 71 a 71 b Tone sequence controller Input Output to horns and (bass) Output to horns and (treble) 59 51 51 e Alternator DC voltage at rectifier DC voltage at rectifier with choke coil for daylight operation Trailer signals Supplementary signal transmission from the trailer to the towing vehicle 72 52 Alarm switch (rotating beacon) 75 Radio, cigarette lighter Wiper motor, input (+) Wiper (+), self-parking Wiper (shunt winding) Electrical windshield washer pump Wiper (brake winding) Wiper motor with permanent magnet and third brush (for higher speed) 76 Loudspeaker 77 Door valve control 53 53 a 53 b 53 c 53 e 53 i Table 58 L 58 R 55 Fog lamps 56 56 a 56 b 56 d Headlamps High beam with indicator lamp Low beam (dipped beam) Headlamp-flasher contact 57 Motorcycle parking lamp (also for passenger car, truck etc in some export markets) Parking lamp Parking lamp, left Parking lamp, right 57 a 57 L 57 R 54 54 g 81 81 a 81 b 82 82 a 82 b 82 z 82 y Trailer signals Trailer gladhand assembly and light combination, stop lamp Pneumatic valve for retarder on trailer, electromagnetically actuated Switch, NC contact and changeover contact Input First output (NC contact side) Second output (NC contact side) NO contact Input First output Second output First input Second input Multiple-position switch .. .Bosch Professional Automotive Information Robert Bosch GmbH (Ed.) Bosch Automotive Electrics and Automotive Electronics Systems and Components, Networking and Hybrid Drive 5th... away on uphill gradients This function is integrated in ESP Robert Bosch GmbH (ed.), Bosch Automotive Electrics and Automotive Electronics, DOI 10.1007/978-3-658-01784-2_1, © Springer Fachmedien... fact that the majority of future functions will also be regulated by electrics and electronics The increase in electrics and electronics is associated with a growth in software Even today, software