Bosch Professional Automotive Information Konrad Reif Ed Brakes, Brake Control and Driver Assistance Systems Function, Regulation and Components Bosch Professional Automotive Information Bosch Professional Automotive Information is a definitive reference for automotive engineers The series is compiled by one of the world´s largest automotive equipment suppliers All topics are covered in a concise but descriptive way backed up by diagrams, graphs, photographs and tables enabling the reader to better comprehend the subject There is now greater detail on electronics and their application in the motor vehicle, including electrical energy management (EEM) and discusses the topic of intersystem networking within vehicle The series will benefit automotive engineers and design engineers, automotive technicians in training and mechanics and technicians in garages Konrad Reif Editor Brakes, Brake Control and Driver Assistance Systems Function, Regulation and Components Editor Prof Dr.-Ing Konrad Reif Duale Hochschule Baden-Württemberg Friedrichshafen, Germany reif@dhbw-ravensburg.de ISBN 978-3-658-03977-6 DOI 10.1007/978-3-658-03978-3 ISBN 978-3-658-03978-3 (eBook) Library of Congress Control Number: 2014945109 Springer Vieweg © Springer Fachmedien Wiesbaden 2014 This work is subject to copyright All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer Violations are liable to prosecution under the German Copyright Law The use of general descriptive names, registered names, trademarks, 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 Printed on acid-free paper Springer is part of Springer Science+Business Media www.springer.com Foreword Foreword Braking systems have been continuously developed and improved throughout the last years Major milestones were the introduction of antilock braking system (ABS) and electronic stability program This reference book provides a detailed description of braking components and how they interact in electronic braking systems Complex technology of modern motor vehicles and increasing functions need a reliable source of information to understand the components or systems The rapid and secure access to these informations in the field of Automotive Electrics and Electronics provides the book in the series “Bosch Professional Automotive Information” which contains necessary fundamentals, data and explanations clearly, systematically, currently and application-oriented The series is intended for automotive professionals in practice and study which need to understand issues in their area of work It provides simultaneously the theoretical tools for understanding as well as the applications V VI Contents Contents 2 Motor-vehicle safety 2 Safety systems 4 Basics of vehicle operation 98 Traction control system (TCS) for four wheel drive vehicles 102 Electronic stability program (ESP) 12 Basic principles of vehicle dynamics 102 Requirements 12 Tires 103 Tasks and method of operation 15 Forces acting on a vehicle 104 Maneuvers 22 Dynamics of linear motion 112 Closed-loop control system and 24 Dynamics of lateral motion 26 Definitions controlled variables 118 Micromechanical yaw-rate sensors 120 Steering-wheel-angle sensors 28 Car braking systems 122 Hall-effect acceleration sensors 28 Overview 30 History of the brake 124 Automatic brake functions 36 Classification of car braking systems 124 Overview 38 Components of a car braking system 126 Standard function 39 Brake-circuit configuration 128 Additional functions 40 Car braking-system components 134 Hydraulic modulator 40 Overview 134 Development history 41 Brake pedal 135 Design 42 Brake servo unit 138 Pressure modulation 47 Master cylinder 49 Brake-fluid reservoir 142 Sensors for brake control 49 Pilot-pressure valve 142 Automotive applications 50 Components for braking-force distribution 144 Wheel-speed sensors 54 Brake pipes 148 Hall-effect acceleration sensors 54 Brake hoses 150 Micromechanical yaw-rate sensors 55 Brake fluid 152 Steering-wheel-angle sensors 56 Wheel brakes 154 Sensotronic brake control (SBC) 56 Overview 154 Purpose and function 58 Drum brakes 156 Design 64 Disk brakes 156 Method of operation 70 Brake pads, shoes and disks 158 Active steering 74 Antilock braking system (ABS) 158 Purpose 74 System overview 158 Design 76 Requirements placed on ABS 160 Method of operation 77 Dynamics of a braked wheel 161 Safety concept 78 ABS control loop 161 Benefits of active steering for the driver 82 Typical control cycles 90 Wheel-speed sensors 162 Occupant protection systems 162 Vehicle safety 94 Traction control system (TCS) 162 Seat belts, seat belt pretensioners 94 Tasks 164 Front airbag 94 Function description 167 Side airbag 96 Structure of traction control system (TCS) 168 Components 97 Typical control situations 171 Rollover protection systems Contents 172 Outlook 233 Further development 175 Piezoelectric acceleration sensors 234 Ultrasonic sensors 176 Surface micromechanical acceleration sensors 178 Seat occupancy sensing 236 Instrumentation 236 Information and communication areas 236 Driver information systems 180 Driving assistance systems 238 Instrument clusters 180 Critical driving situations 240 Display types 180 Accident causes, measures 181 Application areas 242 Orientation methods 181 Safety and convenience 242 Orientation 183 Electronic all-around visibility 242 Position-finding 242 Navigation 186 Adaptive cruise control (ACC) 186 System overview 246 Navigation systems 189 Ranging radar 246 Assignment 197 ACC sensor and control unit 246 Application 204 Composite system 246 Method of operation 210 Control and display 252 Piezoelectric tuning-fork yaw-rate sensor 214 Detection and object selection 220 ACC control 254 Workshop technology 227 Further developments 254 Workshop business 258 Diagnostics in the workshop 230 Parking systems 260 Testing equipment 230 Parking aid with ultrasonic sensors 262 Brake testing VII VIII Authors Authors Motor-vehicle safety Adaptive cruise control (ACC) Dipl.-Ing Wulf Post Prof Dr rer nat Hermann Winner, Dr.-Ing Klaus Winter, Basic principles of vehicle dynamics Dipl.-Ing (FH) Bernhard Lucas, Dipl.-Ing Friedrich Kost Dipl.-Ing (FH) Hermann Mayer, Dr.-Ing Albrecht Irion, Car braking systems Dipl.-Phys Hans-Peter Schneider, Dipl.-Ing Wulf Post Dr.-Ing Jens Lüder Car braking-system components Parking systems Dipl.-Ing Wulf Post Prof Dr.-Ing Peter Knoll Wheel brakes Instrumentation Dipl.-Ing Wulf Post Dr.-Ing Bernhard Herzog Antilock braking system (ABS) Orientation methods Dipl.-Ing Heinz-Jürgen Koch-Dücker, Dipl.-Ing Gerald Spreitz, Dipl.-Ing (FH) Ulrich Papert S Rehlich, M Neumann, Traction control system (TCS) Dipl.-Ing Marcus Risse, Dr.-Ing Frank Niewels, Dipl.-Ing Wolfgang Baierl Dipl.-Ing Jürgen Schuh Navigation systems Electronic stability program (ESP) Dipl.-Ing Ernst-Peter Neukirchner, Dipl.-Ing Thomas Ehret Dipl.-Kaufm Ralf Kriesinger, Dr.-Ing Jürgen Wazeck Automatic brake functions Dipl.-Ing (FH) Jochen Wagner Workshop technology Dipl.-Wirtsch.-Ing Stephan Sohnle, Hydraulic modulator Dipl.-Ing Rainer Rehage, Dr.-Ing Frank Heinen, Rainer Heinzmann Peter Eberspächer and the editorial team in cooperation with the Sensors for brake control responsible in-house specialist departments Dr.-Ing Erich Zabler Unless otherwise stated, the authors are all Sensotronic brake control (SBC) Dipl.-Ing Bernhard Kant Active steering Dipl.-Ing (FH) Wolfgang Rieger, ZF Lenksysteme, Schwäbisch Gmünd, Germany Occupant protection systems Dipl.-Ing Bernhard Mattes Driving assistance systems Prof Dr.-Ing Peter Knoll employees of Robert Bosch GmbH Basics ... mechanics and technicians in garages Konrad Reif Editor Brakes, Brake Control and Driver Assistance Systems Function, Regulation and Components Editor Prof Dr.-Ing Konrad Reif Duale Hochschule... sensors 55 Brake fluid 152 Steering-wheel-angle sensors 56 Wheel brakes 154 Sensotronic brake control (SBC) 56 Overview 154 Purpose and function 58 Drum brakes 156 Design 64 Disk brakes 156 Method... rubber layer 16 Belt 17 Tread 18 Sidewall 19 Bead 10 Bead core 11 Valve K Reif (Ed .), Brakes, Brake Control and Driver Assistance Systems, Bosch Professional Automotive Information, DOI 10.1007/978-3-658-03978-3_2,