Automotive mechatronics : Automotive networking, driving stability systems, electronics

Automotive

Mechatronics

Konrad Reif Ed.

Automotive Networking · Driving

Stability Systems · Electronics

Bosch Professional Automotive

Information

Bosch Professional Automotive Information

Bosch rofessional utomotive nformation 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.

P A I

Automotive Mechatronics

Automotive Networking, Driving Stability

Systems, Electronics

Konrad Reif

Editor

ISBN 978-3-658-03974-5 ISBN 978-3-658-03975-2(eBook)

DOI 10.1007/978-3-658-03975-2

Library of Congress Control Number: 2014946887

Springer Vieweg

© Springer Fachmedien Wiesbaden 2015

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

Editor

Prof. Dr.-Ing. Konrad Reif

Duale Hochschule Baden-Württemberg

Friedrichshafen, Germany

[email protected]

Springer Vieweg is part of Springer Science+Business Media

www.springer-vieweg.de

Foreword V

As the complexity of automotive vehicles increases this book presents operational

and practical issues of automotive mechatronics. It is a comprehensive introduction

to controlled automotive systems and provides detailed information of sensors for

travel, angle, engine speed, vehicle speed, acceleration, pressure, temperature, flow,

gas concentration etc. The measurement principles of the different sensor groups are

explained and examples to show the measurement principles applied in different

types.

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 Elec￾tronics provides the book in the series “Bosch Professional Automotive Information”

which contains necessary fundamentals, data and explanations clearly, systemati￾cally, currently and application-oriented. The series is intended for automotive pro￾fessionals 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.

▶ Foreword

VI Contents

2 Basics of mechatronics

2 Mechatronic systems and components

4 Development methods

6 Outlook

8 Architecture

8 Overview

11 Vehicle system architecture

18 Electronic control unit

18 Operating conditions

18 Design

18 Data processing

22 Digital modules in the control unit

26 Control unit software

30 Software Development

44 Basic principles of networking

44 Network topology

48 Network organization

50 OSI reference model

52 Control mechanisms

56 Automotive networking

56 Cross-system functions

57 Requirements for bus systems

59 Classification of bus systems

59 Applications in the vehicle

61 Coupling of networks

61 Examples of networked vehicles

70 Bus systems

70 CAN bus

84 LIN bus

90 Bluetooth

100 MOST bus

111 TTP/C

124 FlexRay

136 Diagnosis interfaces

144 Automotive sensors

144 Basics and overview

147 Automotive applications

150 Details of the sensor market

151 Features of vehicle sensors

152 Sensor classification

154 Error types and tolerance requirements

155 Reliability

158 Main requirements, trends

165 Overview of the physical effects for sensors

167 Overview and selection of sensor

technologies

168 Sensor measuring principles

168 Position sensors

195 Speed and rpm sensors

207 Acceleration sensors

212 Pressure sensors

215 Force and torque sensors

224 Flowmeters

230 Gas sensors and concentration sensors

234 Temperature sensors

244 Imaging sensors (video)

246 Sensor types

246 Engine-speed sensors

248 Hall phase sensors

249 Speed sensors for transmission control

252 Wheel-speed sensors

256 Micromechanical yaw-rate sensors

259 Piezoelectric “tuning-fork” yaw-rate sensor

260 Micromechanical pressure sensors

262 High-pressure sensors

263 Temperature sensors

264 Accelerator-pedal sensors

266 Steering-angle sensors

268 Position sensors for transmission control

271 Axle sensors

272 Hot-film air-mass meters

275 Piezoelectric knock sensors

276 SMM acceleration sensors

278 Micromechanical bulk silicon acceleration

sensors

279 Piezoelectric acceleration sensors

280 iBolt™ force sensor

282 Torque sensor

283 Rain/light sensor

284 Two-step Lambda oxygen sensors

288 LSU4 planar wide-band lambda oxygen

sensor

290 Electric Actuators

290 Electromechanical actuators

295 Fluid-mechanical actuators

296 Electrical machines

302 Electrohydraulic Actuators

302 Application and Function

▶ Contents

Contents VII

302 Requirements

303 Design and Operating Concept

304 Actuator Types

313 Simulations in Development

316 Electronic Transmission Control

316 Drivetrain Management

317 Market Trends

318 Control of Automated Shift Transmission

AST

322 Control of Automatic Transmissions

338 Control of Continuously Variable

Transmission

340 ECUs for Electronic Transmission Control

347 Thermo-Management

349 Processes and Tools Used in

ECU Development

350 Modules for Transmission Control

350 Application

351 Module Types

354 Antilock Braking System (ABS)

354 System overview

356 Requirements placed on ABS

357 Dynamics of a braked wheel

358 ABS control loop

362 Typical control cycles

370 Traction Control System (TCS)

370 Tasks

370 Function description

372 Structure of traction control system (TCS)

373 Typical control situations

374 Traction control system (TCS) for four

wheel drive vehicles

378 Electronic Stability Program (ESP)

378 Requirements

379 Tasks and method of operation

380 Maneuvers

388 Closed-loop control system and controlled

variables

394 Automatic brake functions

394 Overview

396 Standard function

398 Additional functions

404 Hydraulic modulator

404 Development history

405 Design

408 Pressure modulation

412 Sensotronic brake control (SBC)

412 Purpose and function

414 Design

414 Method of operation

416 Overview of common-rail systems

416 Areas of application

417 Design

418 Operating concept

422 Common-rail system for passenger cars

427 Common-rail system for commercial

vehicles

430 High-pressure components of common-rail

system

430 Overview

432 Injector

444 High-pressure pumps

450 Fuel rail (high-pressure accumulator)

451 High-pressure sensors

452 Pressure-control valve

453 Pressure-relief valve

454 Electronic Diesel Control (EDC)

454 System overview

456 Common-rail system for passenger cars

457 Common-rail system for commercial

vehicles

458 Data processing

460 Fuel-injection control

468 Lambda closed-loop control for

passenger-car diesel engines

473 Torque-controlled EDC systems

476 Data exchange with other systems

477 Serial data transmission (CAN)

478 Active steering

478 Purpose

478 Design

480 Method of operation

481 Safety concept

481 Benefits of active steering for the driver

VIII Contents

482 Drive and adjustment systems

482 Power windows

483 Power sunroofs

484 Seat and steering column adjustment

485 Heating, ventilation and air conditioning

485 Electronic heater control

485 Electronically controlled air conditioning

system

488 Vehicle security systems

488 Acoustic signaling devices

489 Central locking system

490 Locking systems

494 Biometric systems

496 Electromagnetic compatibility (EMC) and

interference suppression

496 EMC ranges

497 EMC between different systems in the

vehicle

504 EMC between the vehicle and its

surroundings

508 Guarantee of immunity and interference

suppression

510 Fault diagnostics

510 Monitoring during vehicle operation

(on-board diagnosis)

513 On-board diagnosis system for passenger

cars and light-duty trucks

520 On-board diagnosis system for heavy-duty

trucks

Authors IX

Basics of mechatronics

Dipl.-Ing. Hans-Martin Heinkel,

Dr.-Ing. Klaus-Georg Bürger.

Architecture

Dr. phil. nat. Dieter Kraft,

Dipl.-Ing. Stefan Mischo.

Electronic control units

Dipl.-Ing. Martin Kaiser,

Dr. rer. nat. Ulrich Schaefer,

Dipl.-Ing. (FH) Gerhard Haaf.

Basic principles of networking

Automotive networking

Bus systems

Dipl.-Ing. Stefan Mischo,

Dipl.-Ing. (FH) Stefan Powolny,

Dipl.-Ing. Hanna Zündel,

Dipl.-Ing. (FH) Norbert Löchel,

Dipl.-Inform. Jörn Stuphorn,

Universität Bielefeld,

Dr. Rainer Constapel, Daimler AG Sindelfingen,

Dipl.-Ing. Peter Häussermann,

Daimler AG Sindelfingen,

Dr. rer. nat. Alexander Leonhardi,

Daimler AG Sindelfingen,

Dipl.-Inform. Heiko Holtkamp,

Universität Bielefeld.

Automotive sensors

Sensor measuring principles

Sensor types

Dr.-Ing. Erich Zabler,

Dr. rer. nat. Stefan Finkbeiner,

Dr. rer. nat. Wolfgang Welsch,

Dr. rer. nat. Hartmut Kittel,

Dr. rer. nat. Christian Bauer,

Dipl.-Ing. Günter Noetzel,

Dr.-Ing. Harald Emmerich,

Dipl.-Ing. (FH) Gerald Hopf,

Dr.-Ing. Uwe Konzelmann,

Dr. rer. nat. Thomas Wahl,

Dr.-Ing. Reinhard Neul,

Dr.-Ing. Wolfgang-Michael Müller,

Dr.-Ing. Claus Bischoff,

Dr. Christian Pfahler,

Dipl.-Ing. Peter Weiberle,

Dipl.-Ing. (FH) Ulrich Papert,

Dipl.-Ing. Christian Gerhardt,

Dipl.-Ing. Klaus Miekley,

Dipl.-Ing. Roger Frehoff,

Dipl.-Ing. Martin Mast,

Dipl.-Ing. (FH) Bernhard Bauer,

Dr. Michael Harder,

Dr.-Ing. Klaus Kasten,

Dipl.-Ing. Peter Brenner, ZF Lenksysteme GmbH,

Schwäbisch Gmünd,

Dipl.-Ing. Frank Wolf,

Dr.-Ing. Johann Riegel.

Electric Actuators

Dr.-Ing. Rudolf Heinz,

Dr.-Ing. Robert Schenk.

Electrohydraulic Actuators

Electronic Transmission Control

Modules for Transmission Control

Dipl.-Ing. D. Fornoff,

D. Grauman,

E. Hendriks,

Dipl.-Ing. T. Laux,

Dipl.-Ing. T. Müller,

Dipl.-Ing. A. Schreiber,

Dipl.-Ing. S. Schumacher,

Dipl.-Ing. W. Stroh.

Antilock Braking System (ABS)

Traction Control System (TCS)

Electronic Stability Program (ESP)

Automatic brake functions

Hydraulic modulator

Dipl.-Ing. Friedrich Kost

(Basic Principles of Vehicle Dynamics),

Dipl.-Ing. Heinz-Jürgen Koch-Dücker

(Antilock Braking Systems, ABS),

Dr.-Ing. Frank Niewels and

Dipl.-Ing. Jürgen Schuh

(Traction Control Systems, TCS),

Dipl.-Ing. Thomas Ehret

(Electronic Stability Program, ESP),

Dipl.-Ing. (FH) Jochen Wagner

(Automatic Brake Functions),

Dipl.-Ing. (FH) Ulrich Papert

(Wheel-Speed Sensors),

Dr.-Ing. Frank Heinen and

Peter Eberspächer

 Authors

X Authors

Sensotronic brake control (SBC)

Dipl.-Ing. Bernhard Kant.

Overview of common-rail systems

High-pressure components of common-rail

system

Electronic Diesel Control (EDC)

Dipl.-Ing. Felix Landhäußer,

Dr.-Ing. Ulrich Projahn,

Dipl.-Inform. Michael Heinzelmann,

Dr.-Ing. Ralf Wirth

(Common-rail system),

Ing. grad. Peter Schelhas,

Dipl.-Ing. Klaus Ortner

(Fuel-supply pumps),

Dipl.-Betriebsw. Meike Keller

(Fuel filters),

Dipl.-Ing. Sandro Soccol,

Dipl.-Ing. Werner Brühmann

(High-pressure pumps),

Ing. Herbert Strahberger,

Ing. Helmut Sattmann

(Fuel rail and add-on components),

Dipl.-Ing. Thilo Klam,

Dipl.-Ing. (FH) Andreas Rettich,

Dr. techn. David Holzer,

Dipl.-Ing. (FH) Andreas Koch

(Solenoid-valve injectors),

Dr.-Ing. Patrick Mattes

(Piezo-inline injectors),

Dipl.-Ing. Thomas Kügler

(Injection nozzles),

Dipl.-Ing. (FH) Mikel Lorente Susaeta,

Dipl.-Ing. Martin Grosser,

Dr.-Ing. Andreas Michalske

(Electronic diesel control),

Dr.-Ing. Günter Driedger,

Dr. rer. nat. Walter Lehle,

Dipl.-Ing. Wolfgang Schauer,

Rainer Heinzmann

(Diagnostics).

Active steering

Dipl.-Ing. (FH) Wolfgang Rieger,

ZF Lenksysteme, Schwäbisch Gmünd.

Drive and adjustment systems

Dipl.-Ing. Rainer Kurzmann,

Dr.-Ing. Günter Hartz.

Heating, ventilation and air conditioning

Dipl.-Ing. Gebhard Schweizer,

Behr GmbH & Co., Stuttgart.

Vehicle security systems

Dipl.-Ing. (FH) Jürgen Bowe,

Andreas Walther,

Dr.-Ing. B. Kordowski,

Dr.-Ing. Jan Lichtermann.

Electromagnetic compatibility

Dr.-Ing. Wolfgang Pfaff.

Fault diagnostics

Dr.-Ing. Matthias Knirsch,

Dipl.-Ing. Bernd Kesch,

Dr.-Ing. Matthias Tappe,

Dr,-Ing. Günter Driedger,

Dr. rer. nat. Walter Lehle.

and the editorial team in cooperation with the

responsible in-house specialist departments of

Robert Bosch GmbH.

Unless otherwise stated, the authors are all

employees of Robert Bosch GmbH.

Basics

1 Mechatronic system

Forces, travel, etc. Forces, travel, etc.

Environment

Auxiliary

power

Feedback

Reference

variables

Correcting

variables

Measured

variables

Basic system

(mostly mechanical)

Processor

Actuator

engineering

Sensor

technology

UAE1035E

2 Basics of mechatronics Mechatronic systems and components

#BTJDT
PG
NFDIBUSPOJDT

The term “mechatronics” came about as

a made-up word from mechanics and

electronics, where electronics means

“hardware” and “software”, and mechan￾ics is the generic term for the disciplines

of “mechanical engineering” and “hy￾draulics”. It is not a question of replacing

mechanical engineering by “electronifi￾cation”, but of a synergistic approach

and design methodology. The aim is to

achieve a synergistic optimization of me￾chanical engineering, electronic hard￾ware and software in order to project

more functions at lower cost, less weight

and installation space, and better quality.

The successful use of mechatronics in a

problem solution is dependent upon an

overall examination of disciplines that

were previously kept separate.

Mechatronic systems

and components

Applications

Mechatronic systems and components are

now present throughout almost the entire

vehicle: starting with engine-management

systems and injection systems for gasoline

and diesel engines to transmission control

systems, electrical and thermal energy

management systems, through to a wide

variety of brake and driving dynamics sys￾tems. It even includes communication and

information systems, with many different

requirements when it comes to operability.

Besides systems and components, mecha￾tronics are also playing an increasingly

vital role in the field of micromechanics.

Examples at system level

A general trend is emerging in the further

development of systems for fully automatic

vehicle handling and steering: more and

more mechanical systems will be replaced

by “X-by-wire” systems in future.

K. Reif (Ed.), Automotive Mechatronics, Bosch Professional Automotive Information,

DOI 10.1007/978-3-658-03975-2_1, © Springer Fachmedien Wiesbaden 2015

Basics of mechatronics Mechatronic systems and components 3

A system that was implemented long ago is

the “Drive-by-wire” system, i.e. electronic

throttle control.

“Brake-by-wire” replaces the hydrome￾chanical connection between the brake

pedal and the wheel brake. Sensors record

the driver’s braking request and transmit

this information to an electronic control

unit. The unit then generates the required

braking effect at the wheels by means of

actuators.

One implementation option for

“Brake-by-wire” is the electrohydraulic

brake (SBC, Sensotronic Brake Control).

When the brake is operated or in the event

of brake stabilization intervention by the

electronic stability program (ESP), the SBC

electronic control unit calculates the re￾quired brake pressure setpoints at the in￾dividual wheels. Since the unit calculates

the required braking pressures separately

for each wheel and collects the actual val￾ues separately, it can also regulate the

brake pressure to each wheel via the

wheel-pressure modulators. The four

pressure modulators each consist of an

inlet and an outlet valve controlled by

electronic output stages which together

produce a finely metered pressure reg￾ulation.

Pressure generation and injection are

decoupled in the Common Rail System.

A high-pressure rail, i.e. the common rail,

serves as a high-pressure accumulator,

constantly providing the fuel pressure re￾quired for each of the engine’s operating

states. A solenoid-controlled injector with

a built-in injection nozzle injects fuel di￾rectly into the combustion chamber for

each cylinder. The engine electronics re￾quest data on accelerator pedal position,

rotational speed, operating temperature,

fresh-air intake flow, and rail pressure in

order to optimize the control of fuel me￾tering as a function of the operating condi￾tions.

Examples at component level

Fuel injectors are crucial components in

determining the future potential of Diesel￾engine technology. Common-rail injectors

are an excellent example of the fact that an

extremely high degree of functionality

and, ultimately, customer utility can only

be achieved by controlling all the physical

domains (electrodynamics, mechanical en￾gineering, fluid dynamics) to which these

components are subjected.

In-vehicle CD drives are exposed to partic￾ularly tough conditions. Apart from wide

temperature ranges, they must in particu￾lar withstand vibrations that have a critical

impact on such precision-engineered sys￾tems.

In order to keep vehicle vibration away

from the actual player during mobile de￾ployment, the drives normally have a

spring damping system. Considerations

about reducing the weight and installation

space of CD drives immediately raise ques￾tions concerning these spring-damper sys￾tems. In CD drives without a damper sys￾tem, the emphasis is on designing a me￾chanical system with zero clearances and

producing additional reinforcement for

the focus and tracking controllers at high

frequencies.

Only by combining both measures

mechatronically is it possible to achieve

good vibration resistance in driving

mode. As well as reducing the weight by

approx. 15 %, the overall height is also

reduced by approx. 20 %.

The new mechatronic system for electri￾cally operated refrigerant motors is based

on brushless, electronically commutated

DC motors (BLDC’s). Initially, they are

more expensive (motor with electronics)

than previous DC motors equipped with

brushes. However, the overall optimization

approach brings benefits: BLDC motors

can be used as “wet rotors” with a much

simpler design. The number of separate

parts is therefore reduced by approx. 60 %.

2 Model library for a micromechanical yaw-rate sensor

Comb-like

structures

Detection

electrodes

Rigid

bodies

Elastic

bodies

Bending

beams

Segment

of a circle

Divided

stator comb

Undivided

stator comb

From

segments

of a circle

From

segments

of a circle

From

segments

of a rectangle

From

segments

of a rectangle

Electro￾mechanical

components

Mechanical

components

Microsystem

UAE0942-1E

4 Basics of mechatronics Mechatronic systems and components

In terms of comparable cost, this more

robust design doubles the service life,

reduces the weight by almost half and

reduces the overall length by approx. 40 %.

Examples in the field of micromechanics

Another application for mechatronics is

the area of micromechanical sensor sys￾tems, with noteworthy examples such as

hot-film air-mass meters and yaw-rate

sensors.

Because the subsystems are so closely

coupled, microsystems design also re￾quires an interdisciplinary procedure that

takes the individual disciplines of mechan￾ical components, electrostatics and possi￾bly fluid dynamics and electronics into

consideration.

Development methods

Simulation

The special challenges that designers face

when developing mechatronic systems are

the ever shorter development times and

the increasing complexity of the systems.

At the same time, it is vital to ensure that

the developments will result in useful

products.

Complex mechatronic systems consist of

a large number of components from differ￾ent physical domains: hydraulic compo￾nents, mechanical components and elec￾tronic components. The interaction be￾tween these domains is a decisive factor

governing the function and performance

of the overall system. Simulation models

are required to review key design deci￾sions, especially in the early development

stages when there is no prototype avail￾able.